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OM-359 196 831G December 2001 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source R Syncrowave 250 DX And Non-CE Models 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 Miller is the first welding help you figure out what the problem is. The equipment manufacturer in parts list will then help you to decide which the U.S.A. to be registered to the ISO 9001 Quality System exact part you may need to fix the problem. Standard. Warranty and service information for your particular model are also provided. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. 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. TABLE OF CONTENTS WARNING This product, when used for welding or cutting, 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.) The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW 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. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 3 3 4 5 5 5 SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 11 SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Automation 10-Pin Connection (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . 3-10. TIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . . 3-12. Front Panel Display For TIG AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . 3-15. Front Panel Display For Stick AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 13 13 15 16 17 17 18 19 19 20 22 25 26 28 30 31 32 SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (Requires . . . . Optional Sequence Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Selecting TIG Starting Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Amperage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14. Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15. Pulse Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16. High Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19. Final Slope Control And Final Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 33 35 35 35 36 7 8 8 38 40 42 44 45 45 46 48 50 51 52 52 53 54 (Continued) TABLE OF CONTENTS 4-20. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 55 56 SECTION 5 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 58 58 59 60 61 SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SECTION 7 – HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 63 63 64 SECTION 8 – SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC . . . . . . . OR AC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 8-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 65 66 SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 67 68 69 SECTION 10 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 1-4. 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-359 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-359 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. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. OM-359 Page 3 1-5. 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-359 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 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des 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 ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. 1-2. Dangers relatifs au soudage à l’arc Y Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité. Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Y Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants. D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel. D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. UN CHOC ÉLECTRIQUE peut tuer. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. 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. Des matériels mal installés ou mal mis à la terre présentent un danger. Il y a DU 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 indiquées dans la partie entretien avant de toucher les pièces. D Ne jamais toucher les pièces électriques sous tension. D Porter des gants et des vêtements de protection secs ne comportant pas de trous. D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre. D D D Ne pas se servir de source électrique àcourant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique àcourant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique àcourant électrique 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. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). D Installer et mettre à la terre correctement cet 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 En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution. D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. D D D D D D D Eloigner votre tête des fumées. Ne pas respirer les fumées. A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué. Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. OM-359 Page 5 LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc. D Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. D Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. D Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité). D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie. D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. D Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. DES PARTICULES VOLANTES peuvent blesser les yeux. D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. OM-359 Page 6 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D D Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher des parties chaudes à mains nues D Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. D D Porteurs de stimulateur cardiaque, restez à distance. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. D Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. Si des BOUTEILLES sont endommagées, elles pourront exploser. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. D Ne jamais souder une bouteille pressurisée – risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état. D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille. D Maintenir le chapeau de protection 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 CGA énumérées dans les normes de sécurité. 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place 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 dimensionné et protégé avant de mettre l’appareil en service. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. LA CHUTE DE L’APPAREIL peut blesser. D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire. D Utiliser un engin d’une capacité appropriée pour soulever l’appareil. D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. D D D D D D Prévoir une période de refroidissement, respecter le cycle opératoire nominal. D Réduire le courant ou le cycle opératoire avant de recommancer le soudage. LE SOUDAGE À L’ARC risque de provoquer des interférences. D Ne pas obstruer les passages d’air du poste. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gachette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles. D D D D D D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 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-359 Page 7 1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Règles de sécurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes : 1 Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. OM-359 Page 8 2 3 4 5 Garder les câbles ensembles en les torsadant ou en les attachant avec du ruban adhésif. Mettre tous les câbles du côté opposé de l’opérateur. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. Garder le poste de soudage et les câbles le plus loin possible de vous. Relier la pince de masse le plus près possible de la zone de soudure. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est alors recommandé de respecter les consignes ci–dessus. SECTION 2 – DEFINITIONS 2-1. 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. 1.3 2.2 2.3 3.2 4 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 OM-359 Page 9 2-2. Torch/Cable Holder Label 1 1 3 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 2-3. Weld Cable Connection Label 1 1 2 3 2 3 4 4 OM-359 Page 10 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. Welding sparks or arcing from unused electrode can cause explosion or fire. Do not connect more than one electrode cable to any single weld output terminal. Disconnect cables for process not in use. Have only one welding circuit (process) connected at any given time — never two. 2-4. 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 Input Postflow Timer Preflow Timer High Frequency Continuous High Frequency Gas (Supply) Gas Input Gas Output Increase/Decrease Of Quantity On Off Percent Direct Current Balance Control Maximum Cleaning Maximum Penetration Electrode Positive Electrode Negative Final Slope Meter Single-Phase Line Connection U0 Rated No Load Voltage (Average) U1 Primary Voltage U2 Conventional Load Voltage I1 Primary Current I2 Rated Welding Current X Duty Cycle IP Degree Of Protection I1eff Maximum Effective Supply Current I1max Rated Maximum Supply Current S 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 4T 4 Step Trigger Operation Sequence OM-359 Page 11 SECTION 3 – INSTALLATION 3-1. 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 Rating Label Use rating label to determine input power needs. 4 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. Location And Airflow 4 1 3 18 in (460 mm) 18 in (460 mm) Ref. ST-117 264-C / ST-802 455-B OM-359 Page 12 3-2. Dimensions And Weights Dimensions A D C Height 33-1/4 in (845 mm) Width 22-1/2 in (572 mm) Length 25 in (635 mm) A 25 in (635 mm) B 1-25/64 in (35 mm) C 1-5/8 in (41 mm) D 20-5/8 in (524 mm) E 19-15/16 (506 mm) F 22-1/4 (565 mm) G 1-5/32 in (30 mm) H 1/2 in (13 mm) Dia B C G E Front F Ref. ST-196 584-B H 8 Holes Weight 389 lbs (176 kg) 3-3. Specifications Amperes Input at AC Balanced Rated Load Output, 60 Hz, Single-Phase Rated Welding Output PFC** 200V 230V NEMA Class I (40) – 200 Amperes, 28 Volts AC, 60% Duty Cycle No PFC 88 77 *3.3 *2.8 NEMA Class I (40) – 200 Amperes, 28 Volts AC, 60% Duty Cycle With PFC 60 52 *55.3 *49.5 NEMA Class II (40) – 250 Amperes, 30 Volts AC, 40% Duty Cycle No PFC 110 96 *3.3 *2.8 NEMA Class II (40) – 250 Amperes, 30 Volts AC, 40% Duty Cycle With PFC 82 71 *55.3 *49.5 460V 575V KVA 38 31 17.6 8.6 *1.5 *1.1 *.59 *.29 26 21 12.06 8.11 *24.5 *19.6 *11.2 *.39 48 38 21.98 11.76 *1.5 *1.1 *.59 *.29 35 28 16.32 11.81 *24.5 *19.6 *11.2 *1.93 KW Amperage Range Max OCV 5 – 310A 80V 5 – 310A 80V 5 – 310A 80V 5 – 310A 80V *While idling **Power Factor Correction OM-359 Page 13 3-5. 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 5 – 310A 80V 5 – 310A 80V 5 – 310A 80V 5 – 310A 80V Amperage Range Max OCV 5 – 310A 80V 5 – 310A 80V 5 – 310A 80V 5 – 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-359 Page 14 3-4. 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 5-4), 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 / SB-116 198 OM-359 Page 15 3-5. Volt-Ampere Curves Non Ce Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 194 385-A / 194 384-A Ce Models 205 631 / 205 632 OM-359 Page 16 3-6. 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. Work Electrode Ref. ST-801 972 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 3-7. 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 ST-801 972 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. *The remaining sockets are not used. OM-359 Page 17 3-8. Automation 10-Pin Connection (Optional) Socket F A Start/Stop B Gas C Output disabled D Chassis ground E Final slope – collector F Final slope – emitter G Pulse lockout – collector H Pulse lockout – emitter I Valid arc – collector J Valid arc – emitter E G D J H Socket Information For 10-Pin Receptacle RC3 C I A B Y Turn off power before connecting to receptacle Ref. ST-801 972 Definitions Of Inputs And Outputs Inputs A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100ms, but less than 3/4 seconds) starts and stops weld output. B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initiation. C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to time out, and HELP 13 will be displayed on the meters. Outputs Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30 VDC. Final Slope - output is on when in Final Slope. Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10 Hz. Arc On - output is on when the contactor is on and there is less than 50 load volts. OM-359 Page 18 3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle Y Turn Off power before connecting to receptacle. 1 4 Gas Valve In Fitting Located on rear of unit. 2 3 5 Gas Valve Out Fitting Fittings have 5/8-18 right-hand 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. 6 5 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). 2 6 1 115 V 15 Amp AC Receptacle Receptacle is protected from overload by circuit breaker CB1 (see Section 5-2). Front View Rear View Ref. ST-801 972 / Ref. ST-801 973 / Ref. ST-157 858 3-10. TIG Connections Y Turn Off power before making connections. 1 Gas In Connection Connect gas hose from gas supply to gas in fitting. 2 Switch is shown in DCEN (direct current electrode negative) position for TIG HF Impulse DCEN welding. For front panel control dispay, see Section 3-11. For TIG AC welding, place switch in AC position (see Section 4-2). For TIG AC front panel control dispay, see Section 3-12. 2 3 3 4 5 11/16, (21 mm), 3/4 in 6 Remote 14 Receptacle Connect desired remote control to Remote 14 receptacle. 5 Tools Needed: Work Weld Output Terminal Connect work lead to work weld output terminal. 1 4 Output Selector Switch (See Section 4-2) Electrode Weld Output Terminal Connect TIG torch to electrode weld outout terminal. 6 Gas Out Connection Connect torch gas hose to gas out fitting. 802 734-B OM-359 Page 19 3-11. 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 4-1 for description of controls). 1 OM-359 Page 20 CE Models 1 OM-359 Page 21 3-12. Front Panel Display For TIG AC 1 Front Panel Correct front panel display for basic TIG AC welding. . For all front panel switch pad controls: press switch pad to turn on light and enable function. NOTE: Green on nameplate indicates a TIG function (see Section 4-1 for description of controls). 1 OM-359 Page 22 CE Models 1 OM-359 Page 23 Notes OM-359 Page 24 3-13. 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. 4 4 1 Output Selector Switch (See Section 4-2) Switch is shown in DCEP (direct current electrode positive) position for Stick DCEP welding. For front panel control dispay, see Section 3-14. For Stick AC welding, place switch in AC position (see Section 4-2). For Stick AC front panel control dispay, see Section 3-15. 3 2 Tools Needed: 11/16, (21 mm), 3/4 in 802 733-B OM-359 Page 25 3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 1 Front Panel Correct front panel display for basic Stick DCEP welding. . For all front panel switch pad controls: press switch pad to turn on light and enable function. NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls). 1 OM-359 Page 26 CE Models 1 OM-359 Page 27 3-15. Front Panel Display For Stick AC 1 Front Panel Correct front panel display for basic Stick AC welding. . For all front panel switch pad controls: press switch pad to turn on light and enable function. NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls). 1 OM-359 Page 28 CE Models 1 OM-359 Page 29 3-16. Electrical Service Guide NOTE All values in both tables were calculated at 60% duty cycle. 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/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil 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/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil 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-359 Page 30 3-17. Placing Jumper Links Y Disconnect and lockout/tagout input power before installing or moving jumper links. Check input voltage available at site. 1 200 VOLTS 230 VOLTS 460 VOLTS 2 L L L L L L S-083 566-C 2 230 VOLTS L 460 VOLTS L L L Jumper Link Label Check label – only one is on unit. Jumper Links Move jumper links to match input voltage. Close and secure access door, or go on to Section 3-18. 575 VOLTS L L S-010 587-B 1 Tools Needed: 3/8 in Ref. ST-801 973-B OM-359 Page 31 3-18. Connecting Input Power 1 GND/PE Earth Ground 1 7 9 3 8 When making connections in the line disconnect device, connect the Green Or Green/Yellow conductor first. Install conductors into a deenergized line disconnect device. 4 6 Make connections to machine first and supply last. 2 Connect Green Or Green/Yellow GND/PE Conductor First Tools Needed: 3/8 in 5 3 Ref. ST-801 973-B Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Have only qualified persons make this installation. See rating label on unit and check input voltage available at site. 1 2 3 Line Disconnect Device Input Conductors Grounding Conductor Select size and length using Section 3-16. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size. OM-359 Page 32 4 Strain Relief Route conductors through strain relief. 5 Machine Grounding Terminal 6 Line Terminals Y Make input power connections to the welding power source before making connections into a deenergized line disconnect device. Connect green or green/yellow grounding conductor to machine grounding terminal first. Then connect input conductors to line terminals. Close access door. 7 Disconnect Device (Supply) Grounding Terminal 8 Disconnect Device Line Terminals Y In the deenergized line disconnect device, connect green or green/yellow grounding conductor to supply grounding terminal first, never to a line terminal. Be sure grounding conductor goes to an earth ground. Connect input conductors to line terminals. 9 Overcurrent Protection Select type and size using Section 3-16 (fused disconnect switch shown). Close door on line disconnect device. SECTION 4 – OPERATION 4-1. Controls A. For 200/230/460 Volts And Non CE Units 12 1 2 3 4 5 6 7 13 11 10 9 8 14 . Top row of lights in upper left corner are On 5 See Section 4-10 10 Postflow Time Control Green on nameplate indicates a TIG function, Gray indicates a Stick function. 6 See Section 4-14. 1 7 for SMAW. Bottom row are On for GTAW. Process Control Voltmeter Ammeter See Section 4-10 See Section 4-3. Amperage Adjustment Control 11 Balance/DIG Control See Section 4-12. See Section 4-11. 12 Pulser Controls (Optional) See Section 4-4. 8 See Section 4-15. 3 2 Amperage Control Output Selector Switch See Section 4-2. 13 Sequence Controls (Optional) See Section 4-5. 9 See Section 4-17. 4 Use switch to turn unit Off and On. Output Control Start Mode Control See Section 4-9. Power Switch 14 High Frequency Control See Section 4-16. Ref. ST-196 616 / Ref. ST-194 388-B / Ref. ST-801 972 OM-359 Page 33 B. For CE Units 12 1 2 3 4 6 5 7 13 11 10 9 8 14 . Top row of lights in upper left corner are On 5 See Section 4-10 10 Postflow Time Control Green on nameplate indicates a TIG function, Gray indicates a Stick function. 6 See Section 4-14. 1 7 for SMAW. Bottom row are On for GTAW. Process Control Voltmeter Ammeter See Section 4-10 See Section 4-3. Amperage Adjustment Control 11 Balance/DIG Control See Section 4-12. See Section 4-11. 12 Pulser Controls (Optional) See Section 4-4. 8 See Section 4-15. 3 2 Amperage Control Output Selector Switch See Section 4-2. 13 Sequence Controls (Optional) See Section 4-5. 9 See Section 4-17. 4 Use switch to turn unit Off and On. Output Control Start Mode Control See Section 4-9. Power Switch 14 High Frequency Control See Section 4-16. Ref. ST-196 764 / Ref. ST-196 766 / Ref. ST-801 972 OM-359 Page 34 4-2. Output Selector Switch 1 (CE Nameplate) 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 also change Process control, Current control, Output control, and Start Mode control settings to properly function with latest Output Selector switch setting. 4-3. Process Control (CE Nameplate) 1 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. 1 1 NOTE: Lit LED indicates selected mode. When Output Selector switch position changes, LED may change position, based upon last selection. Ref. ST-196 616 / Ref. ST-196 764 4-4. Amperage Control (CE Nameplate) 1 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 3-7). NOTE: Lit LED indicates selected mode. 1 1 When Output Selector switch position changes, LED may change position, based upon last selection. OM-359 Page 35 4-5. Output Control Remote (Standard)Torch Trigger Operation 2 2 1 1 (CE Nameplate) 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 Y Weld output terminals are energized when power is On, and Output On LED is lit. Use control to select front panel, trigger hold, or remote output control. NOTE: Lit LED indicates selected mode. For weld output, press button to toggle LED to On position. OM-359 Page 36 Release For Maintained Switch 2 Remote Trigger (Standard) Operation For remote output control, press button to toggle LED to Remote position (see Section 3-7). Torch trigger operation is as shown. NOTE: Initial weld amperage and final amperage is controlled by the remote device, not by the welding power source. 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. Application: Use Remote Trigger when the operator desires to use a foot pedal or finger amperage control. When Output Selector switch (see Section 4-2) position changes, Output control LED will always switch to Remote. When Output On is selected, HF and gas control are disabled. Trigger Hold (2T) 3 3 (CE Nameplate) Current (A) 2T Torch Trigger Operation Weld Amps Final Slope Initial Amps Final Amps Postflow Preflow Push & Release Trigger In Less Than 3/4 Sec. Push & Release Trigger In Less Than 3/4 Sec. 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 5-4). 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. NOTE: Amperage is controlled by the welding power source. Application: Use Trigger Hold (2T) when long extended welds are made. Trigger Hold (2T) can help to reduce operator fatigue. OM-359 Page 37 4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional Sequence Controls) 4T Torch Trigger Operation If unit is equipped with optional Sequence Controls (see Section 4-17), 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 4-7. 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 4-17), 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 4-7. Current (A) Weld Amps Final Slope Initial Amps Final Amps Postflow Preflow Push & Release Trigger OM-359 Page 38 Push & Release Trigger Push & Release Trigger Push & Release Trigger Mini Logic Operation If unit is equipped with optional Sequence Controls (see Section 4-17), 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 4-7. 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-359 Page 39 4-7. 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 4-6 for 4T Operation. Proceed to Section 4-6 for Mini Logic operation. H-2 Proceed to Section 4-6 for 4T Momentary operation. NOTE: These features are only available when optional Sequencer is installed. SEL HĆ4E = 4T Momentary (See Section 4-6) SEL SEL = Mini Logic (See Section 4-6) = 4T (See Section 4-6) H-4 H4L 3 OM-359 Page 40 2 (CE Nameplate) Front Panel 1 SEL H-2 SEL HĆ4E = 4T Momentary (See Section 4-6) SEL SEL = Mini Logic (See Section 4-6) = 4T (See Section 4-6) H-4 H4L 3 OM-359 Page 41 4-8. 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-359 Page 42 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. 1 (CE Nameplate) 4 SEL -2- 2 3 OM-359 Page 43 4-9. 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. See Section 4-16 for adjusting high frequency intensity. Application: When Off is selected, use the scratch method to start an arc for both the SMAW and GTAW processes. 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. When Lift-Arc is selected, start arc as follows: Application: 2 TIG Electrode 3 Workpiece Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method. 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-359 Page 44 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. 4-10. Meters 1 Voltmeter Voltmeter displays average voltage (to the nearest 0.1 V) at the weld output terminals. 1 2 Ammeter Use meter to preset amperage. Meter displays average weld amperage output of unit to nearest ampere when welding. NOTE: Meters are self-calibrating. No adjustment available. 2 4-11. Amperage Adjustment Control 1 (CE Nameplate) 1 1 Amperage Adjustment Control Use control to adjust amperage, and preset amperage on ammeter (see Section 4-10). 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 4-15). For spot welding, use Amperage Adjust control to select from 5–300 amps of peak amperage (see Section 4-20). OM-359 Page 45 4-12. Balance/DIG Control 1 (CE Nameplate) 1 Balance/DIG Control Balance Control (AC GTAW): 1 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. 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 More Penetration 10 More 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 7 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 (AC And DC SMAW): When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage. When setting is increased, shortcircuit amperage at low arc voltage increases. 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-359 Page 46 Notes OM-359 Page 47 4-13. Preflow Time Control 1 3 00.2 SEL 2 Use control to set length of time (0.2, 0.4, 0.6, 0.8, 1.0, 2.0 or 4.0 seconds) gas flows before welding starts. 1 Process Control 2 Power Switch 3 Meters To change preflow time, proceed as follows: OM-359 Page 48 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.2] [SEL]. The factory preflow default setting is 0.2 seconds. To change preflow Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. Application: 1 3 (CE Nameplate) 00.2 SEL 2 OM-359 Page 49 4-14. Postflow Time Control 1 (CE Nameplate) 1 1 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 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). OM-359 Page 50 4-15. Pulse Controls (Optional) 1 3 2 1 4 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 4 Pulse Frequency Ranges from 0.25–10.0 pps (pulses per second). Control is used to determine appearance of weld bead. 4 Peak Time A range of 5–95% of each pulse cycle can be spent at the peak amperage level. 5 Percent (%) Peak Time Control Setting Pulsed Output Waveforms PPS (50%) Bkg Amp Balanced Peak Amp More Time At Peak Amperage More Time At Background Amperage (80%) (20%) Peak amperage (5–310 amps), is set with the Amperage Adjustment control (see Section 4-1). Peak amperage is the highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage. 5 Pulsed Output Waveforms Example shows affect changing the Peak Time control has on the pulsed output waveform. Application: Pulsing refers to the alternating raising and lowering of the weld output at a specific rate. The raised portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level between them (called the background amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding. Pulsing can also be used for filler material addition technique training. NOTE: Function is enabled, when LED is lit. OM-359 Page 51 4-16. High Frequency Control 1 Ref. ST-801 972 Y Do not use high frequency while Shielded Metal Arc Welding (SMAW). 1 NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the HF Intensity control towards maximum, may help to restabilize the arc. High Frequency Control . As high frequency intensity is increased, the possibility of inter- For GTAW, use control to set HF intensity. Set as low as possible. fering with local electronic devices, especially communication equipment, also increases. Set control as low as possible to avoid such interference. Application: If HF is present at the tungsten, the control is set high enough. 4-17. Sequence Controls (Optional) 1 Initial Time Control See Section 4-18. 2 5 1 Initial Amperage Control See Section 4-18. 3 3 Final Slope Control See Section 4-19. 4 Final Amperage Control See Section 4-19. 5 Spot Time Control See Section 4-20. 4 2 (CE Nameplate) 5 1 2 3 4 Ref. ST-196 616 / Ref. ST-196 764 OM-359 Page 52 4-18. Initial Time Control And Initial Amperage Control 1 (CE Nameplate) Initial Time Control Indicator light is on when Initial Time control function is active. 1 1 NOTE: Initial Sequence control function is inactive when Spot Time function is active. 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-359 Page 53 4-19. Final Slope Control And Final Amperage Control 1 (CE Nameplate) Note: Final Slope control function is inactive when Spot Time function is active. 1 1 Final Slope Control Indicator light is on when Final Slope control 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. 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 4-20). 2 2 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. 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. 4-20. Spot Time Control 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 4-17). 1 Used with the (GTAW) TIG Spot process, generally with a direct current electrode negative (DCEN) set-up. Use control to select 0–15 seconds of spot time. (CE Nameplate) 1 Use Amperage Adjust control (see Section 4-11) to set amperage. Application: TIG spot welding is used for joining thinner materials that are in close contact with the fusion method. A good example would be joining coil ends. NOTE: Function is enabled, when LED is lit. OM-359 Page 54 4-21. Timer/Cycle Counter 1 2 3 1 2 3 4 5 6 (CE Nameplate) 1 2 3 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. 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. OM-359 Page 55 4-22. Resetting Unit To Factory Default Settings (All Models) 2 1 3 4 5 1 2 3 4 Process Control Amperage Control Output Control Start Control OM-359 Page 56 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). 2 1 3 4 CE Models 5 OM-359 Page 57 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean And Tighten Weld Terminals Repair Or Replace Cracked Weld Cables Replace Unreadable Labels Replace Cracked Parts Adjust Spark Gaps 14-Pin Cord Torch Cable Gas Hose 6 Months Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly OR 5-2. Circuit Breaker CB1 Y Turn off power before resetting breaker. 1 1 Circuit Breaker CB1 If CB1 opens, high frequency and output to the 115 volts ac duplex receptacle stop. Press button to reset breaker. Ref. ST-801 972 OM-359 Page 58 5-3. Adjusting Spark Gaps Y Turn Off power before adjusting spark gaps. Open access door. 1 Tungsten End Of Point Replace point if tungsten end disappears; do not clean or dress tungsten. 2 2 1 Spark Gap Normal spark gap is 0.012 in (0.305 mm). If adjustment is needed, proceed as follows: 3 Adjustment Screws Loosen screws. Place gauge of proper thickness in spark gap. 4 3 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap. Tighten screws. Adjust other gap. Reinstall access door. Tools Needed: 0.012 in (0.305 mm) 5/32 in Ref. ST-801 972-A / Ref. S-0043 OM-359 Page 59 5-4. Voltmeter/Ammeter Help Displays . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 0 Help 0 Display Indicates a short in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent. 1 Help1 Display An SCR overcurrent condition has occurred. Turn power off and back on to correct condition. If problem continues, contact a Factory Authorized Service Agent. 2 Help 2 Display Indicates a malfunction in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent. 3 Help 3 Display Indicates the transformer of the unit has overheated. The unit has shut down to allow 0 1 the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled. 4 Help 4 Display Indicates a malfunction in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent. 5 Help 5 Display Indicates the rectifier assembly of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled. 6 Help 6 Display Help 9 Display 10 Help 10 Display Indicates Remote Output control is activated. Release Remote Output control to clear help message. 11 Help 11 Display Indicates Output Selector switch is not in correct position (see Section 4-2). Indicates a non-allowable set-up on the front panel. Help 7 Display 13 Help 13 Display Not used. 8 9 Indicates a short in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent. 12 Help 12 Display Not used. 7 Not used. AIC option, output enable signal broken causing weld output to stop, but gas continues to flow. Help 8 Display 2 3 4 V V V V V HLP HLP HLP HLP HLP A A A A A --0 --1 --2 --3 --4 5 6 7 8 9 V V V V V HLP HLP HLP HLP HLP A A A A A --5 --6 --7 --8 --9 10 11 12 13 V V V V HLP HLP HLP HLP A A A A -10 -11 -12 -13 OM-359 Page 60 5-5. Troubleshooting NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit. Refer to Section 5-4 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 3-18). Check and replace line fuse(s), if necessary (see Section 3-18). Check for proper input power connections (see Section 3-18). Check for proper jumper link position (see Section 3-17). 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 4-1). 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 4-1). Have Factory Authorized Service Agent check unit. Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-6). Clean and tighten all weld connections. Check position of Output Selector control (see Section Figure 4-1). If using remote control, check position of Amperage Adjustment control (see Section 4-1). No control of weld output. 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 4-1). Make sure Amperage control is in proper position (see Section 4-1). No output from duplex receptacle RC2 and no high frequency. Reset circuit breaker CB1 (see Section 5-2). Lack of high frequency; difficulty in starting GTAW arc. Reset circuit breaker CB1 (see Section 5-2). Select proper size tungsten. Check High Frequency Intensity control setting (see Figure 4-1). Be sure torch cable is not close to any grounded metal. Check cables and torch for cracked insulation or bad connections. Repair or replace. Check spark gaps (see Section 5-3). 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-359 Page 61 SECTION 6 – ELECTRICAL DIAGRAM 194 381-H Figure 6-1. Circuit Diagram All Models OM-359 Page 62 SECTION 7 – HIGH FREQUENCY 7-1. 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 7-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) 10 14 9 8 7 3 2 13 1 4 Sources of Direct High-Frequency Radiation 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table 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-359 Page 63 7-3. Correct Installation 7 Weld Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 8 4 8 Ground all metal objects and all wiring in welding zone using #12 AWG wire. Nonmetal Building Ground workpiece if required by codes. 9 Metal Building 8 8 11 10 Ref. S-0695 / Ref. S-0695 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable. 2 Center Point of Welding Zone Midpoint between high-frequency source and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all directions. 4 Weld Output Cables Keep cables short and close together. OM-359 Page 64 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 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. Ground water pipes every 50 ft (15 m). 10 Windows and Doorways 7 Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. External Power or Telephone Lines Locate high-frequency source at least 50 ft (15 m) away from power and phone lines. 8 Grounding Rod Consult the National Electrical Code for specifications. 11 Overhead Door Track Ground the track. SECTION 8 – SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac/dc_gtaw 2/2000 Y Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten ) Amperage Range - Gas Type♦ - Polarity Electrode Diameter DC – Argon – Electrode Negative/Straight Polarity DC – Argon – Electrode Positive/Reverse Polarity AC – Argon AC – Argon – .010” Up to 25 * Up to 20 Up to 15 .020” 15-40 * 15-35 5-20 Balanced Wave 2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens .040” 25-85 * 20-80 20-60 1/16” 50-160 10-20 50-150 60-120 3/32” 135-235 15-30 130-250 100-180 1/8” 250-400 25-40 225-360 160-250 5/32” 400-500 40-55 300-450 200-320 3/16” 500-750 55-80 400-500 290-390 1/4” 750-1000 80-125 600-800 340-525 .010” Up to 15 * Up to 15 Up to 10 .020” 5-20 * 5-20 10-20 .040” 15-80 * 10-60 20-30 1/16” 70-150 10-20 50-100 30-80 3/32” 125-225 15-30 100-160 60-130 1/8” 225-360 25-40 150-210 100-180 5/32” 360-450 40-55 200-275 160-240 3/16” 450-720 55-80 250-350 190-300 1/4” 720-950 80-125 325-450 250-400 .010” * * Up to 20 Up to 15 .020” * * 15-35 5-20 .040” * * 20-80 20-60 1/16” * * 50-150 60-120 3/32” * * 130-250 100-180 1/8” * * 225-360 160-250 5/32” * * 300-450 200-320 3/16” * * 400-550 290-390 1/4” * * 600-800 340-525 Pure Tungsten (Green Band) Zirconium Alloyed Tungsten (Brown Band) ♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended. Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. OM-359 Page 65 8-2. Preparing Tungsten Electrode For Welding Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away. A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines 1 1 2 2 Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2-1/2 Times Electrode Diameter 1 1 2 Stable Arc Flat 2 Diameter of this flat determines amperage capacity. 3 3 Grinding Wheel Grinding wheel should be dedicated to grinding tungsten only. 4 4 Straight Ground 1 2 3 Arc Wander Point Grinding Wheel Ideal Tungsten Preparation – Stable Arc 1 2 3 Grinding wheel should be dedicated to grinding tungsten only. 4 Radial Ground 1 2 Tungsten Electrode Balled End 4 Wrong Tungsten Preparation – Wandering Arc B. Preparing Tungsten For Conventional AC Welding Y Understand and follow safety symbols at start of Section 9-1 before preparing tungsten. 1 1 – 1-1/2 Times Electrode Diameter 2 OM-359 Page 66 Ball end of tungsten by applying AC amperage recommended for a given electrode diameter (see Section 8-1). Let ball on end of the tungsten take its own shape. SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) 9-1. Positioning The Torch Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. . For additional information, see 3 your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process. 2 1 Workpiece Make sure workpiece is clean before welding. 4 2 Work Clamp Place as close to the weld as possible. 90° 3 4 5 6 1 Torch Filler Rod (If Applicable) Gas Cup Tungsten Electrode Select and prepare tungsten according to Sections 8-1 and 8-2. Guidelines: 10–15° 4 5 6 10–25° The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in diameter, gas cup should be a minimum of 3/16 in diameter. Tungsten extension is the distance the tungsten extends out gas cup of torch. 5 6 The tungsten extension should be no greater than the inside diameter of the gas cup. Arc length is the distance from the tungsten to the workpiece. 1/16 in 3/16 in Bottom View Of Gas Cup Ref. ST-161 892 OM-359 Page 67 9-2. Torch Movement During Welding Tungsten Without Filler Rod 75° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75° Welding direction Form pool Tilt torch Remove rod 15° Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B OM-359 Page 68 9-3. Positioning Torch Tungsten For Various Weld Joints 90° Butt Weld And Stringer Bead 70° 20° 20° “T” Joint 75° 10° 15° 20-40° Lap Joint 75° 15° 30° 90° Corner Joint 75° 15° ST-162 003 / S-0792 OM-359 Page 69 SECTION 10 – STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure Y Weld current starts when electrode touches workpiece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 5 2 3 4 2 Work Clamp Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 10-2). 3 6 1 Workpiece Make sure workpiece is clean before welding. 7 4 5 6 Insulated Electrode Holder Electrode Holder Position Arc Length Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass. Tools Needed: stick 12/96 – ST-151 593 OM-359 Page 70 7014 7018 7024 Ni-Cl 308L ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL LOW SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE PENETRATION EP 6011 AC 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DC* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSITION 6013 6010 ELECTRODE 6010 & 6011 100 50 DIAMETER ELECTRODE 10-2. Electrode and Amperage Selection Chart MIN. PREP, ROUGH HIGH SPATTER LOW SMOOTH, EASY, FASTER LOW CAST IRON LOW STAINLESS *EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) Ref. S-087 985-A 10-3. Striking an Arc – Scratch Start Technique 1 1 2 3 Electrode Workpiece Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 2 3 S-0049 10-4. Striking an Arc – Tapping Technique 1 1 2 3 2 Electrode Workpiece Arc Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 3 S-0050 OM-359 Page 71 10-5. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 10-6. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 S-0053-A 10-7. Good Weld Bead Characteristics 1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 4 5 1 2 3 4 No Overlap Good Penetration into Base Metal 5 S-0052-B OM-359 Page 72 10-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED S-0061 10-9. Electrode Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better. 1 2 1 2 3 Stringer Bead – Steady Movement Along Seam Weave Bead – Side to Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. 3 S-0054-A OM-359 Page 73 10-10. Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) 30° Single V-Groove Weld Good for materials 3/16 – 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. 4 3 Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/16 in (5 mm). S-0662 10-11. Lap Joint 30° Or Less 30° Or Less 1 1 1 2 Move electrode in circular motion. 3 Single-Layer Fillet Weld Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 3 2 Electrode Single-Layer Fillet Weld Multi-Layer Fillet Weld S-0063 / S-0064 10-12. Tee Joint 1 2 Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 1 2 45° Or Less Electrode Fillet Weld For maximum strength weld both sides of upright section. 2 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 10-9. Remove slag before making another weld pass. 1 3 S-0060 / S-0058-A / S-0061 OM-359 Page 74 10-13. Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 10-14. Troubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 10-15. Troubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage. OM-359 Page 75 10-16. Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique. Keep arc on leading edge of weld puddle. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 10-17. Troubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed. 10-18. Troubleshooting – Excessive Penetration Excessive Penetration – weld metal melting through base metal and hanging underneath weld. Excessive Penetration Possible Causes Excessive heat input. Good Penetration Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. OM-359 Page 76 10-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 10-20. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands. Practice technique. 10-21. Troubleshooting – Distortion Distortion – contraction of weld metal during welding that forces base metal to move. Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Corrective Actions Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds. OM-359 Page 77 47 48 49 45 OM-359 Page 78 46 44 Figure 11-1. Main Assembly 41 40 42 50 43 34–Fig. 11-3 39 1 2 3 57 4 38 56 5 35 36 6–Fig. 11-2 29 55 37 28 27 33 30 26 7 8 31 25 23 24 32 54 20 21 22 53 9 19 18 16 15 17 52 51 14 12 11 13 10 SECTION 11 – PARTS LIST . Hardware is common and not available unless listed. 802 609-E Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly . . . 1 . . . . . PC1 . . . . . 203 899 . . . . . . . . . . . . . . . . . . . . . . 186 914 . . . . . . . . PLG13, 15 . . . 131 054 . . . . . . . . . . PLG10 . . . . 130 203 . . . . . . . . . . PLG14 . . . . 115 092 . . . . . . . . . . PLG4 . . . . . 115 093 . . . . . . . . . . PLG17 . . . . 131 052 . . . . . . . . . . PLG16 . . . . 115 091 . . . 2 . . . . . . . . . . . . . . . . 195 778 . . . 3 . . . . . . . . . . . . . . . . 190 512 . . . 4 . . . . . PC2 . . . ♦190 734 . . . 5 . . . . . PC3 . . . ♦190 738 . . . 6 . . . . . . . . . . . . . . . . 196 762 . . . 7 . . . . . . . . . . . . . . . . 204 658 . . . . . . . . . . . . . . . . . . . . . . 194 590 . . . 8 . . . . . . . . . . . . . . . . 205 726 . . . 9 . . . . . . R3 . . . . . . 201 133 . . . 10 . . . . . . . . . . . . . . +204 291 . . . . . . . . . . . . . . . . . . . . . . 127 363 . . . . . . . . . . . . . . . . . . . . . . 168 384 . . . 11 . . . . . . . . . . . . . . . . 168 343 . . . 12 . . . . . . . . . . . . . . . . 184 057 . . . . . . . . . . . . . . . . . . . . . . 189 491 . . . 13 . . . . . . . . . . . . . . . . 605 227 . . . 14 . . . . . GS1 . . . . . 133 873 . . . . . . . . . . . . . . . . . . . . . . 602 969 . . . 15 . . . . . . . . . . . . . . . . 010 146 . . . 16 . . . . . . . . . . . . . . . . 176 272 . . . 17 . . . . . . . . . . . . . . . . 202 485 . . . . . . . . . . . CR1 . . . . . 186 162 . . . 18 . . . . . . . . . . . . . . . . 184 058 . . . 19 . . . . . . 1T . . . . . . 199 312 . . . 20 . . . . . . . . . . . . . . . . 150 783 . . . 21 . . FM1, FM2 . . . 188 706 . . . 22 . . . . . . . . . . . . . . . . 187 807 . . . 23 . . . . . . . . . . . . . . . . 204 293 . . . 24 . . . . . . . . . . . . . . . . 026 627 . . . 25 . . . . T1, Z1 . . . . . 194 379 . . . 25 . . . . T1, Z1 . . . . . 196 715 . . . 25 . . . . T1, Z1 . . . . . 196 711 . . . . . . . . . . . TH1 . . . . . . 201 443 . . . . . . . . . . PLG1 . . . . . 202 119 . . . . . . . . . . PLG7 . . . . . 202 116 . . . . . . . . . . PLG8 . . . . . 202 117 . . . . . . . . . . PLG11 . . . . 202 118 . . . 26 . . . . . . . . . . . . . . . . 200 647 . . . 27 . . . . . . . . . . . . . . . . 192 862 . . . 28 . . . . . SR1 . . . . . 196 485 . . . . . . . . . . . . . . . . . . . . . . 605 603 . . . 29 . . . . . . . . . . . . . . . . 184 052 . . . 30 . . . . C5, C6 . . . . 111 634 . . . 31 . . . . . TE1 . . . . . . 202 790 . . . . . . . . . . . . . . . . . . . . . . 083 426 . . . . . . . . . . . . . . . . . . . . . . 038 618 . . . . . . . . . . . . . . . . . . . . . . 601 835 . . . . . . . . . . . . . . . . . . . . . . 601 836 . . . . . . . . . . . . . . . . . . . . . . 038 888 . . . . . . . . . . . . . . . . . . . . . . 038 887 . . . . . . . . . . . . . . . . . . . . . . 010 913 . . . . . . . . . . . . . . . . . . . . . . 010 915 . . . . . . . . . . . . . . . . . . . . . . 602 207 . . . . . . . . . . . . . . . . . . . . . . 175 479 . . . Circuit Card Assy, Interface (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Display, LED Numeric 7 Segment 3 Digit (LED’s 18 – 23) . . . . . . . . . 6 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Actuator Push Button Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . Stand–off, No 6–32 X .6406 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . Circuit Card, Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Circuit Card, Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Hf Control Box Assy, ( Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . Label, Miller 12.563 X 5.376 Horizontal Syncrowav . . . . . . . . . . . . . . . . 2 . . . Top, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Resistor, WW Fxd 400 W 35 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . 1 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Label, Warning Electric Shock And Incorrect Input P . . . . . . . . . . . . . . . 1 . . . Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h . . . . . . . . . . . . . . . 1 . . . Door, Primary Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Spacer, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Nut, 750–14 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . . 1 . . . Plug, Protective No 6 Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 1 . . . Conn, Clamp Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Baffle, Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Fan, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Block, Terminal Fast–on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Blade, Fan 9.000 5wg 39deg .312 Bore Cw Plstc . . . . . . . . . . . . . . . . . 2 . . . Motor, Fan 230v 50/60hz 1550 Rpm .312 Dia Shaft . . . . . . . . . . . . . . . 2 . . . Bracket, Mtg Motor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . Support, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Gasket, Lifting Eye Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Xfmr/Stabilizer Assy, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Xfmr/Stabilizer Assy, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Xfmr/Stabilizer Assy, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Thermistor, NTC 10k ohm @ 25 deg C 27.5 in lead . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Bracket, Support Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . Rectifier Assy, (Figure 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Tubing, Gl Acryl 1.000–1.036 Idxspool Nat Fa1 . . . . . . . . . . . . . . . . . 0.875 . . . Baffle, Cap Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . Term Assy, Pri 1ph 3v (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Terminal Board, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Link, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . Nut, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . Nut, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . Stud, pri board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . Stud, pri board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . Washer, flat brs .187 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . Washer, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . 4 . . . . Washer, lock .255 ID x .489 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . Link, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 OM-359 Page 79 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly (continued) . . . . . . . . . . . . . . . . . . . . . . 190 161 . . . Lug, Univ W/Screw 1/O–14 Wire .266std . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . +196 584 . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 436 . . . Label, Ground/Protectiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . . . 189 224 . . . End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . 197 026 . . . HF Panel Assy, Lower (Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . S1 . . . . . . 128 757 . . . Switch, Tgl Dpst 60a 600vac Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . R5 . . . . . . 198 547 . . . Rheostat, Ww 25. W 1.5 Ohm Fric Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . S5 . . . . . . 201 121 . . . Switch Assy, Polarity With Leads And Hardware (Dx) . . . . . . . . . . . . . . . . . 38 . . . . . . . . . . . . . . . . 204 305 . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 397 . . . Blank, Snap–in Nyl .312 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 860 . . . Blank, Snap–in Nyl .187 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 983 . . . Blank, Snap–in Nyl .500 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . 097 922 . . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 041 . . . Label, Indicator Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . +196 492 . . . Door, Access Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 327 . . . Label, Warning General Precautionary Static&wire Fe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 363 . . . Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . . . . 175 952 . . . Plastic, Handle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . . 194 388 . . . Nameplate, Miller Syncrowave 250DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . . 196 766 . . . Nameplate, Miller Syncrowave 250DX (Wordless) . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . . . . . . . . . . 184 066 . . . Door Spark Gap Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . . . . . . . . . . . . . . 196 616 . . . Plate, Indicator Syncrowave 250DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . . . . . . . . . . . . . . 196 764 . . . Plate, Indicator Syncrowave 250DX (Wordless) . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . . . 183 332 . . . Knob, Pointer .570 Dia X .125 Id W/Spring Clip . . . . . . . . . . . . . . . . . . . . . . 46 . . . . . . . . . . . . . . . . 174 991 . . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip–.21 . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . 204 416 . . Drawer, Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . 204 313 . . Drawer, Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . . . . . . . . . 204 307 . . Slide, Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 204 314 . . Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . . 204 389 . . HOLDER, Torch/Cable (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 . . . . . . . . . . . . . 200 920 . . . . Door, Torch/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . . . . . . . 200 922 . . . . Housing, Torch/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . 494 907 . . SCREW, k50 x 20 pan hd – trx pld pt thread forming . . . . . . . . . . . . . . . . . . . 55 . . C20-23 . . ♦203 517 . . CAPACITOR, polyp film 150 uf 250 VAC can 10% . . . . . . . . . . . . . . . . . . . . . 56 . . . . . . . . . . . . ♦129 201 . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 . . . . . . . . . . . . . 205 669 . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 4 1 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 2 1 2 2 2 2 4 2 1 ♦ OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-359 Page 80 Item No. Dia. Mkgs. Part No. Description 196 762 . . . 1 . . . . . . G1 . . . . . . 199 854 . . . . . . . . . . . . . . . . . . . . . . 199 855 . . . . . . . . . . . . . . . . . . . . . . 199 856 . . . . . . . . . . . . . . . . . . . . . . 196 455 . . . 2 . . . . . . . . . . . . . . . . 184 068 . . . 3 . . . . . . C3 . . . . . . 201 197 . . . 4 . . . . . . R8 . . . . . . 188 067 . . . 5 . . . C11, C19 . . . 195 552 . . . 6 . . . . . . R2 . . . . . . 189 132 . . . 7 . . . . . . R1 . . . . . . 186 468 . . . 8 . . . . . . . . . . . . . . . . 010 493 . . . 9 . . . . . . . . . . . . . . . . 196 576 . . . 10 . . . . . . T3 . . . . . . 074 398 Quantity Figure 11-2. HF Control Box Assembly (Figure 11-1 Item 6) . . . Spark Gap Assy, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holder, Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Points, Spark Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Spark Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor, Polyp Met Film .002uf 4400vacpnlmtg . . . . . . . . . . . . . . . . . . . . Resistor, ww fxd 100 w 200 ohm w/clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor, Polyp Met Film 20. Uf 250 Vac 10% . . . . . . . . . . . . . . . . . . . . . . Resistor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor, Ww Fxd 100 W 50 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing, Snap–in Nyl .625 Id X .875 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . Hf, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xfmr, High Voltage 115v Pri 3600v Sec 30 Ma . . . . . . . . . . . . . . . . . . . . 1 1 4 4 1 1 1 2 1 1 1 1 1 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. . Hardware is common and not available unless listed. 7 6 8 5 4 5 3 2 1 10 Figure 11-2. HF Control Box Assembly 9 802 756-A OM-359 Page 81 Item No. Dia. Mkgs. Part No. 197 026 . . . 1 . . . . . . . . . . . . . . . . 197 022 . . . 2 . . . . . . . . . . . . . . . . 193 415 . . . 3 . RC2/CB1/C12 . 201 153 . . . . . . . . . . . . . . . . . . . . . . 156 734 . . . 4 . . . . . RC1 . . . . . 201 127 . . . . . . . . . . PLG5 . . . . . 143 976 . . . 5 . . . . . CM1 . . . . . 197 220 . . . 6 . . . . . . . . . . . . . . . . 089 120 . . . 7 . . . . . . . . . . . . . . . . 155 527 . . . 8 . . . . . . . . . . . . . . . . 120 854 . . . 9 . . . C13, C14 . . . 196 499 . . . 10 . . . . . . . . . . . . . . . . 157 317 . . . 11 . . . . . . T4 . . . . . . 199 487 . . . . . . . . . . . . . . . . . . . . . . 203 474 . . . 12 . . . . . . . . . . . . . . . . 157 318 . . . 13 . . . . . . . . . . . . . . . . 039 047 Description Quantity Figure 11-3. HF Panel Assembly, Lower (Figure 11-1 Item 34) . . . Panel, Lower Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector, Faston 1/4 Ring W/75deg Bend . . . . . . . . . . . . . . . . . . . . . . . . . Receptacle, W/Leads And Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 010–32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . . . Harness, Assy 14 Pin Recpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module, Filter .1mf 500vdc 8 Ckt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamp, Hose .375 – .450 Clp Dia Slfttng Green . . . . . . . . . . . . . . . . . . . . . . Hose, Nprn Brd No 1 X .250 Id X 28.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ftg, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holder, Hf Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil, Hf Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Kit, DX Coupling Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Holder, Hf Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 1 1 1 1 1 2 1 1 2 1 1 1 1 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. . Hardware is common and 2 not available unless listed. 1 3 4 6 7 5 9 10 8 11 9 12 802 757 13 Figure 11-3. HF Panel Assembly, Lower OM-359 Page 82 Item No. Dia. Mkgs. Part No. Description 196 485 ... ... ... ... ... ... 1 2 3 4 5 6 . . . Mod 1, 2 . . . . 196 760 . . . . . . . . . . . . . . . . 196 191 . . . . . HD1 . . . . . 191 941 . . . . . TH2 . . . . . . 188 431 . . . . . . . . . . . . . . . . 196 171 . . C7, 8, 9, 10 . . 190 460 Quantity Figure 11-4. HF Rectifier Assembly (Figure 11-1 Item 28) . . . Thyristor, SCR Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transducer, Current Hall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermister, NTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 1 1 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. . Hardware is common and not available unless listed. 1 4 2 5 1 3 6 5 Ref. 802 609-A Figure 11-4. Rectifier Assembly OM-359 Page 83 Effective January 1, 2001 (Equipment with a serial number preface of “LB” 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. 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 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. 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 Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * 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 Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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 Induction Heating Coils and Blankets * * * * * APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 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. 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 10/01 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service 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. 1/02
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