Miller | KK213455 | Owner Manual | Miller SYNCROWAVE 350 LX User manual

Miller SYNCROWAVE 350 LX User manual
OM-356
188694F
October 1999
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
Syncrowave 350 LX
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 help you
Miller is the first welding equip- figure out what the problem is. The parts list
ment manufacturer in the U.S.A. will then help you to decide which exact part
to be registered to the ISO 9001
you may need to fix the problem. Warranty and
Quality System Standard.
service information for your particular model
are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
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.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
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.)
OM-356F
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . .
3-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Amperage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Setting Pulse Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. High Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Optional Sequence Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Sequence Selection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Start Time/Spot Time Control And Start Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Crater Time Control And Final Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Start/Crater Sequence Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. 4T Sequence Selection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
Manufacturer’s Address:
Declares that the product:
1635 W. Spencer Street
Appleton, WI 54914 USA
Syncrowave 350LX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 60974−1
(November 1997 − Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 10/95
Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
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 − do not use work clamp or work 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-356 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-356 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-356 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-356 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 5/97
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 Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
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
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 − ne pas utiliser le connecteur de pièce ou le câble de
retour.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
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-356 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-356 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-356 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-356 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
1.1
1.2
1.3
2
1
1.1
2.1
1.3
1.2
2.2
2.3
3
2
2.1
2.2
3.1
2.3
3.2
3
3.1
3.2
3.3
3.3
4
4.1
4
4.1
+
+
5
+
6
5
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
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. Don’t weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
6
+
S-176 254-A
OM-356 Page 9
2-2. Manufacturer’s Rating Label For CE Products
OM-356 Page 10
2-3. Symbols And Definitions
NOTE
A
V
Some symbols are found only on CE products.
Amperes
Panel−Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Volts
Do Not Switch
While Welding
Arc Force (DIG)
Spot Timer
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
Crater Time
Meter
Single-Phase
U2
X
Conventional Load
Voltage
Line Connection
I1max
Rated Maximum
Supply Current
U0
Rated No Load
Voltage (Average)
U1
Primary Voltage
I1
Primary Current
I2
Rated Welding
Current
IP
Degree Of
Protection
I1eff
Maximum Effective
Supply Current
S
4T
Duty Cycle
1
1
Hz
Single-Phase
Combined AC/DC
Power Source
Hertz
Electrode
Work
Thickness Gauge
Spark Gap
Seconds
Final Current
Start Time
Start Amperage
Peak Time
Spot Sequence
Start/Crater Sequence
Start Sequence
Crater Sequence
Pulser
Background Amps
Pulse Frequency
4 Step Trigger Operation Sequence
OM-356 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-801 971
OM-356 Page 12
3-2. Dimensions And Weights
Dimensions
A
B
Height
38-1/4 in (972 mm) with retractable lifting eye down
Width
22-1/2 in (572 mm)
Length
25 in (635 mm)
A
25 in (635 mm)
B
23-5/8 in (600 mm)
C
1-3/8 in (35 mm)
D
7/8 in (22 mm)
E
19-15/16 (506 mm)
F
22-1/4 (565 mm)
G
1/2 in (13 mm) Dia
D
C
E
Front
F
Weight
Ref. ST-184 046
G 4 Holes
515 lbs (234 kg)
3-3. Specifications
Rated
Welding
Output
Amperes Input at AC Balanced Rated Load Output,
50/60 Hz, Single-Phase
PFC
**
200V
220V
230V
400V
440V
460V
520V
575V
KVA
KW
NEMA Class I
(60) − 300
Amperes, 32
Volts AC, 60%
Duty Cycle
No
PFC
129
5*
117
5*
112
4*
65
3*
58
2*
56
2*
49
2*
45
2*
21.8
0.9*
14.3
0.4*
With
PFC
98
69*
89
63*
85
60*
49
35*
44
31*
43
30*
37
26*
34
24*
19.3
14.0*
14.0
0.4*
NEMA Class II
(40) − 350
Amperes, 34
Volts AC, 40%
Duty Cycle
No
PFC
150
5*
137
5*
131
4*
75
3*
68
2*
66
2*
57
2*
53
2*
24.5
0.9*
17.7
0.4*
With
PFC
118
69*
107
63*
103
60*
59
35*
53
31*
52
30*
45
26*
41
24*
23.9
14.0*
17.7
0.4*
Amperage
Range
Max
OCV
3 − 400A
80V
3 − 400A
80V
*While idling
**Power Factor Correction
OM-356 Page 13
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 350 Amperes (60 Hz Models Only)
4 Minutes Welding
60% Duty Cycle At 300 Amperes
6 Minutes Welding
6 Minutes Resting
4 Minutes Resting
Overheating
A
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / SB-190 276
3-5. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
ssb1.1 10/91 − ST-
OM-356 Page 14
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
Weld Output
Terminals
Electrode
Work
Ref. ST-801 972
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
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
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
Socket*
A
A
B
K
J
Socket Information
A
24 volts dc.
B
Contact closure to A completes 24 volts dc contactor control circuit.
C
Command reference; 0 to +10 volts dc output to remote control.
D
Remote control/feedback circuit common.
E
0 to +10 volts dc input command signal from remote control.
K
Chassis common.
F
Current feedback, 1 volt per 100 amperes.
H
Voltage feedback, 1 volt per 10 arc volts.
I
H
C L N
D M
G
E F
Ref. ST-801 972
*The remaining sockets are not used.
OM-356 Page 15
3-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle
Y Turn Off power before connecting to receptacle.
1
Gas Valve In Fitting
Located on rear of unit.
2
4
Gas Valve Out Fitting
Fittings have 5/8-18 right-hand
threads.
3
5
3
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
4
Regulator/Flow Gauge
Connect regulator/flow gauge to
gas cylinder.
Connect customer supplied gas
hose between regulator/flow gauge
and gas in fitting.
5
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
6
115 V AC Receptacle
Receptacle is protected from overload by circuit breaker CB1 (see
Section 5-2).
6
1
2
Tools Needed:
5/8, 3/4, 1-1/8 in
Ref. ST-801 972 / Ref. ST-801 973 / Ref. ST-157 858
OM-356 Page 16
3-9. Electrical Service Guide
NOTE
All values 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
129
117
112
65
58
56
49
45
Max Recommended Standard Fuse Or
Circuit Breaker Rating In Amperes
175
150
150
80
70
70
60
60
4
4
4
8
8
8
8
10
111
(34)
134
(41)
146
(45)
196
(60)
238
(72)
260
(79)
332
(101)
273
(83)
6
6
6
8
8
8
10
10
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor
Length In Feet (Meters)
Min Grounding Conductor Size In AWG/
Kcmil
Reference: 1996 National Electrical Code (NEC)
S-0092-J
50/60 Hertz Models
With Power Factor Correction
Input Voltage
200
220
230
400
440
460
520
575
Input Amperes At Rated Output
98
89
85
49
44
43
37
34
Max Recommended Standard Fuse Or
Circuit Breaker Rating In Amperes
150
125
125
70
70
60
60
50
4
4
4
8
8
8
10
10
117
(36)
141
(43)
154
(47)
204
(62)
246
(75)
269
(82)
230
(70)
281
(86)
6
6
6
8
8
10
10
10
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor
Length In Feet (Meters)
Min Grounding Conductor Size In AWG/
Kcmil
Reference: 1996 National Electrical Code (NEC)
S-0092-J
OM-356 Page 17
3-10. Placing Jumper Links And Connecting Input Power
Check input voltage available at
site.
1
Jumper Link Label
Check label − only one is on unit.
200 VOLTS
230 VOLTS
460 VOLTS
2
Jumper Links
Move jumper links to match input
voltage.
L
L
L
L
L
L
3
S-083 566-C
2
230 VOLTS
460 VOLTS
575 VOLTS
Select size and length using Section 3-9.
4
L
L
L
L
L
L
S-010 587-B
Input And Grounding
Conductors
Line Disconnect Device
Select type and size of overcurrent
protection using Section 3-9.
Close and secure primary door.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
GND/PE
Earth Ground
Connect GND/PE
Conductor First
1
4
L1 (U)
L2 (V)
3
Connect GND/PE
Conductor First
3/8 in
Tools Needed:
Ref. ST-801 973-A
OM-356 Page 18
SECTION 4 − OPERATION
4-1. Controls
A. For 200/230/460 Volts And Non CE Units
1
2
3
4
6
5
7
13
14
15
16
11
17
12
10
9
8
18
. Top row of lights in upper left corner are
1
On for SMAW. Bottom row are On for
GTAW.
Process Control
See Section 4-7
See Section 4-9.
7
Pulse Controls:
Amperage Adjustment
Control
See Section 4-8.
See Section 4-3.
8
2
See Section 4-2.
Current Control
See Section 4-4.
3 Output Control
See Section 4-5.
4 Start Mode Button
See Section 4-6.
5
Voltmeter
9
Output Selector Switch
Power Switch Push Buttons
Use buttons to turn unit Off and On.
10 Postflow Time Control
See Section 4-11.
11 Preflow Time Control
See Section 4-7
See Section 4-10.
6
12 Balance/DIG Control
Ammeter
13 Pulser On/Off Switch
See Section 4-12.
14 Background Amperage Control
See Section 4-12.
15 Pulses Frequency Control
See Section 4-12.
16 Peak Time Control
See Section 4-12.
17 Sequence Controls (Optional)
See Section 4-14.
18 High Frequency Control
See Section 4-13.
Ref. ST-183 200-A / Ref. ST-183 260-A / Ref. ST-801 972
OM-356 Page 19
B. For CE Units
1
2
3
4
6
5
7
13
14
15
16
11
17
12
10
9
8
18
. Top row of lights in upper left corner are
1
On for SMAW. Bottom row are On for
GTAW.
Process Control
See Section 4-7
See Section 4-9.
7
Pulse Controls:
Amperage Adjustment
Control
See Section 4-8.
See Section 4-3.
8
2
See Section 4-2.
Current Control
See Section 4-4.
3 Output Control
See Section 4-5.
4 Start Mode Button
See Section 4-6.
5
Voltmeter
9
Output Selector Switch
Power Switch Push Buttons
Use buttons to turn unit Off and On.
10 Postflow Time Control
See Section 4-11.
11 Preflow Time Control
See Section 4-7
See Section 4-10.
6
12 Balance/DIG Control
Ammeter
13 Pulser On/Off Switch
See Section 4-12.
14 Background Amperage Control
See Section 4-12.
15 Pulses Frequency Control
See Section 4-12.
16 Peak Time Control
See Section 4-12.
17 Sequence Controls (Optional)
See Section 4-14.
18 High Frequency Control
See Section 4-13.
Ref. ST-191 372 / Ref. ST-191 371-A / Ref. ST-801 972
OM-356 Page 20
4-2. Output Selector Switch
1
(CE Nameplate Shown)
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.
Use switch to select (DCEN) Direct
Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output without changing
weld output cable connections.
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.
Ref. ST-191 372
4-3. Process Control
1
(CE Nameplate Only)
1
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.
NOTE: Lit LED indicates selected
mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
Ref. ST-191 372
OM-356 Page 21
4-4. Current Control
1
(CE Nameplate Only)
1
1
Current Control
Use control to select front panel or
remote current control.
For front panel current control,
press button to toggle LED to Panel
position.
For remote current control, press
button to toggle LED to Remote 14
position (see Section 3-7).
NOTE: Lit LED indicates selected
mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
4-5. Output Control
1
Output Control
Y Weld output terminals are
energized when power is On,
and Output On LED is lit.
(CE Nameplate Only)
Use control to select front panel or
remote output control.
For weld output, press button to
toggle LED to On position.
1
1
For remote output control, press
button to toggle LED to Remote 14
position (see Section 3-7).
NOTE: Lit LED indicates selected
mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
When Output On is selected, HF
and gas control are disabled.
OM-356 Page 22
4-6. Start Mode
(CE Nameplate Only)
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 4-13 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.
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.
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:
When Lift-Arc is selected, start arc as
follows:
Application:
HF Continuous is used when the AC GTAW
process is required.
2
TIG Electrode
NOTE: Lit LED indicates selected mode.
3
Workpiece
Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted.
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 seconds,
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.
OM-356 Page 23
4-7. 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.
2
4-8. Amperage Adjustment Control
1
(CE Nameplate Only)
1
1
Amperage Adjustment Control
Use control to adjust amperage,
and preset amperage on ammeter
(see Section 4-7). 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 3 to 200 A.
For pulse welding, use Amperage
Adjust control to select from 3−400
amps of peak amperage (see Section 4-12).
For spot welding, use Amperage
Adjust control to select from 3−400
amps of peak amperage (see Section 4-15).
OM-356 Page 24
4-9. Balance/DIG Control
(CE Nameplate Only)
1
1
1
Balance/DIG Control
Balance Control (AC GTAW):
Control changes the AC output
square wave. Rotating the control
towards 10 provides deeper penetration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
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
Arc
50% Electrode
Positive
Set control to 7 and adjust as necessary. Joint configuration, set-up,
process variables, and oxide thickness may affect setting.
50% Electrode
Negative
More Penetration
10
More Cleaning
0
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.
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.
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
DIG Control (AC And DC SMAW):
45% Electrode
Negative
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
4-10. Preflow Time Control
(CE Nameplate Only)
1
1
1
Preflow Time Control
Use control to set length of time that
gas flows (0−10 seconds) before
arc starts.
Application:
Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc
starting.
OM-356 Page 25
4-11. Postflow Time Control
1
(CE Nameplate Only)
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.
OM-356 Page 26
4-12. Setting Pulse Controls
1
1
2
3
4
On/Off Switch
Use switch 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 Only)
1
2
3
4
Pulse Frequency
A range 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 (3−400 amps), is
set with the Amperage Adjustment control (see Section A).
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.
OM-356 Page 27
4-13. High Frequency Control
1
Y Do not use high frequency while Shielded Metal Arc Welding (SMAW).
1
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.
Ref. ST-801 972
4-14. Optional Sequence Controls
1
Sequence Selection Switch
See Section 4-15.
2
1
2
Start Time/Spot Time Control
See Section 4-16.
4
3
Start Current Control
See Section 4-16.
4
Crater Time Control
See Section 4-17.
5
Final Current Control
See Section 4-17.
5
3
(CE Nameplate Only)
4
2
5
3
1
OM-356 Page 28
Ref. ST-191 372
4-15. Sequence Selection Switch
1
(CE Nameplate Only)
1
Sequence Selection Switch
Switch controls Off, Start, Crater, Start/Crater, 4t, and Spot
functions. Place switch in desired position.
1
Off− Place switch in Off position
when Sequence Selection functions are not desired.
4-16. Start Time/Spot Time Control And Start Current Control
1
(CE Nameplate Only)
Sequence Selection Switch
Place switch in Start position.
2
1
1
Start Time/Spot Time Control
Use control to select 0−15 seconds
of start time.
3
Start Current Control
Use start control to select a starting
current (3−400 amps) that is different from the weld current. Note:
Start current can be used with or
without a remote control.
Application:
2
3
2
Start current can be used while
GTAW welding to assist in preheating cold material prior to depositing
filler material, or to ensure a soft
start. Start current can also be used
for SMAW to ensure a more consistent arc strike.
3
OM-356 Page 29
4-17. Crater Time Control And Final Current Control
1
(CE Nameplate Only)
1
1
Sequence Selection Switch
Place switch in Crater position.
2
Crater Time Control
Use control to reduce current
over a set period of time (0−15
seconds) at the end of the weld
cycle when NOT using a remote
current control.
3
Final Current Control
Final current is the current to
which weld current has sloped
down to (0−100% of current set on
Amperage Adjust control).
Application:
2
2
3
OM-356 Page 30
3
Crater Time 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.
4-18. Start/Crater Sequence Controls
1
(CE Nameplate Only)
2
1
1
Sequence Selection Switch
Place switch in Start/Crater position.
Start Time/Spot Time
Control
Use control to select 0−15 seconds of start time.
3
Start Current Control
Use start control to select a starting current (3−400 amps) that is
different from the weld current.
4
Crater Time Control
Use control to reduce current
over a set period of time (0−15
seconds) at the end of the weld
cycle when NOT using a remote
current control.
5
2
2
Final Current Control
Final current is the current to
which weld current has sloped
down to (0−100% of current set
on Amperage Adjust control).
Application:
Start current can be used while
GTAW welding to assist in preheating a cold material prior to
depositing filler material. Start
current can also be used for
SMAW to ensure a more consistent arc strike.
3
3
Crater Time can be used while
GTAW welding when material being welded is crack sensitive, and
the operator is using an on/off
type control to start and stop the
welding process.
NOTE: Use this method when
the function of a remote control is
desired, but only a remote on/off
control is available.
4
4
5
5
OM-356 Page 31
4-19. 4T Sequence Selection Controls
1
(CE Nameplate Only)
1
2
1
Start Sequence Switch −
4T Position
(Specific trigger method) Press
and hold torch trigger to start
Preflow Time and arc at the Start
Current level. The arc will remain
at the Start Current level as long
as the trigger is depressed. Release trigger to change to main
weld current. To end main weld
current, press and hold trigger.
Crater Time begins, and arc
drops to Final Current level and
remains there until trigger is released, at which time arc goes
out, and Postflow Time begins.
While in 4T mode, there is a feature available during the main
weld sequence that allows the
operator to toggle between weld
current and final current. To
switch from weld current to final
current, press and release torch
trigger within 3/4 of a second. To
return to weld current, press and
release torch trigger within 3/4 of
a second again.
2
2
Start Time/Spot Time
Control
Use control to select 0−15 seconds of start time.
3
Start Current Control
Use start control to select a starting current (3−400 amps) that is
different from the weld current.
3
3
4
Crater Time Control
Use control to reduce current
over a set period of time (0−15
seconds) at the end of the weld
cycle when not using a remote
control.
5
4
4
Final Current Control
Final current is the current to
which weld current has sloped
up/down to (0−100% of current
set on Amperage Adjust control).
Application:
Use 4T trigger method when the
functions of a remote current
control are desired, but only a remote on/off control is available.
5
OM-356 Page 32
5
4-20. Spot Time Control
1
(CE Nameplate Only)
1
Sequence Selection Switch −
Spot Position
Used with the (GTAW) TIG Spot
process, generally with a direct current electrode negative (DCEN) setup.
1
2
Start Time/Spot Time Control
Use control to select 0−15 seconds
of spot time.
Use Amperage Adjust control (see
Section 4-8) 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.
2
2
4-21. Timer/Cycle Counter
1
2
Current Control
Output (Contactor) Control
To read timer/cycle counter, hold
Current and Output (contactor) buttons while turning on power.
3
1 2 3
3
1
2
4 5 6
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.
1 2 3
4
4 5 6
(CE Nameplate Only)
OM-356 Page 33
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
Adjust Spark
Gaps
Replace
Cracked
Parts
14-Pin Cord
Torch Cable
Gas Hose
6 Months
Blow Out Or Vacuum Inside,
During Heavy Service, Clean Monthly
OR
Y Warranty is void if machine fails
due to contaminates inside.
5-2. Circuit Breaker CB1
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-356 Page 34
5-3. Adjusting Spark Gaps
Y Turn Off power before
adjusting spark gaps.
Open access door.
1
4
Tungsten End Of Point
Replace point if tungsten end disappears; do not clean or dress
tungsten.
3
2
Spark Gap
Normal spark gap is 0.012 in (0.305
mm).
If adjustment is needed, proceed as
follows:
2
1
3
Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
4
Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
screws. Adjust other gap.
Reinstall access door.
Tools Needed:
0.012 in (0.305 mm)
5/32 in
Ref. ST-801 972 / Ref. S-0043
OM-356 Page 35
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 Help 1 Display
Not used.
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
0
1
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.
4
Help 5 Display
9
Help 9 Display
Indicates a short in the thermal protection circuitry located on the rectifier assembly of the
unit. If this display is shown, contact a Factory Authorized Service Agent.
10 Help 10 Display
Indicates Remote Output control is activated. Release Remote Output control to
clear help message.
11 Help 11 Display
Help 6 Display
Indicates Output Selector switch is not in
correct position (see Section 4-2).
Not used.
2
Help 8 Display
Not used.
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 7 Display
Not used.
8
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
7
3
4
5
V
V
V
V
V
V
HLP
HLP
HLP
HLP
HLP
HLP
A
A
A
A
A
A
−−0
−−1
−−2
−−3
−−4
−−5
6
7
8
9
10
11
V
V
V
V
V
V
HLP
HLP
HLP
HLP
HLP
HLP
A
A
A
A
A
A
−−6
−−7
−−8
−−9
−10
−11
OM-356 Page 36
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 not 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 3-10).
Check and replace line fuse(s), if necessary (see Section 3-10).
Check for proper input power connections (see Section 3-10).
Check for proper jumper link position (see Section 3-10).
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 switch 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.
OM-356 Page 37
Trouble
Remedy
Check for water in torch, and repair torch if necessary.
Fan not operating.
OM-356 Page 38
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
SECTION 6 − ELECTRICAL DIAGRAM
SC-187 950-B
Figure 6-1. Circuit Diagram
OM-356 Page 39
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-356 Page 40
7-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
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.
OM-356 Page 41
Figure 8-1. Main Assembly
OM-356 Page 42
66
67
65
68
69
70
64
71
74
72
73
1
62
63
2
3
12
10
51
5
61
60
52
53
54
55
56
4
6
9
57
58
59
50
75
15 16 18
17
11
13
14
20
49
19
21
8
44
45
46
47
7
23
22
25
24−Fig.3
48
26
43
27
28
42
30
29
41
31
33
32
39
34
35
38
37
36
SECTION 8 − PARTS LIST
. Hardware is common and
not available unless listed.
ST-802 012-B
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . 191 011
. . . 2 . . . . . PC1 . . . . . 196 254
. . . . . . . . . . . . . . . . . . . . . . 186 914
. . . . . . . . PLG13, 15 . . . 131 054
. . . . . . . . . . PLG10 . . . . 165 484
. . . . . . . . . . PLG4 . . . . . 131 055
. . . . . . . . . . PLG14 . . . . 167 333
. . . . . . . . . . . . . . . . . . . . . . 190 512
. . . 3 . . . . . PC2 . . . . . 183 101
. . . 4 . . . . . PC3 . . . ♦183 105
. . . 5 . . . . . . S5 . . . . . . 187 467
. . . . . . . . . . . . . . . . . . . . . . 021 795
. . . . . . . . . . PLG4 . . . . . 131 055
. . . 6 . . . . CR1-3 . . . . . 052 964
. . . . . . . . . . SN1-3 . . . . . 118 625
. . . 7 . . . . . . C2 . . . . . . 031 668
. . . . . . . . . . . . . . . . . . . . . . 168 976
. . . 8 . . . . . . . . . . . . . . . . 108 105
. . . 9 . . . . . . . . . . . . . . . . 184 067
. . . 10 . . . . . . T3 . . . . . . 074 398
. . . 11 . . . . . . G1 . . . . . . 020 623
. . . . . . . . . . . . . . . . . . . . . . 020 622
. . . . . . . . . . . . . . . . . . . . . . 020 603
. . . . . . . . . . . . . . . . . . . . . . 095 621
. . . 12 . . . . . . . . . . . . . . . . 149 951
. . . 13 . . . . . . . . . . . . . . . . 184 068
. . . 14 . . . . . . C3 . . . . . . 191 868
. . . 15 . C1.11 ,18,19 . . 191 944
. . . 16 . . . . . . R8 . . . . . . 188 067
. . . 17 . . . . . . R2 . . . . . . 189 132
. . . 18 . . . . . . R1 . . . . . . 186 468
. . . 19 . . . . . HD1 . . . . . 168 829
. . . 20 . . . . C20-24 . . ♦125 781
. . . 21 . . . . . . . . . . . . . . ♦129 201
. . . 22 . . . . . . . . . . . . . . . . 184 052
. . . 23 . . . . . . . . . . . . . . . . 187 447
. . . 24 . . . . . SR1 . . . . . 187 449
. . . 25 . . . . . . . . . . . . . . . . 184 080
. . . 26 . . . . . . . . . . . . . . . . 184 048
. . . 27 . . . . . . . . . . . . . . . . 187 806
. . . 28 . . . . . . . . . . . . . . . . 155 903
. . . 29 . . . . . . . . . . . . . . . . 155 905
. . . 30 . . . . . . . . . . . . . . . . 184 077
. . . 31 . . . . . . . . . . . . . . . . 187 809
. . . 32 . . . . FM1,2 . . . . . 148 808
. . . 33 . . . . . . . . . . . . . . . . 150 783
. . . 34 . . . . . . . . . . . . . . . . 184 058
. . . 35 . . . . . . . . . . . . . . . . 189 234
. . . . . . . . . . . . . . . . . . . . . . 108 023
. . . 36 . . . . . . . . . . . . . . . . 191 010
. . . . . . . . . . . . . . . . . . . . . . 176 272
. . . . . . . . . . . . . . . . . . . . . . 184 057
. . . 37 . . . . . . GS . . . . . . 133 873
. . . . . . . . . . . . . . . . . . . . . . 605 227
. . . 38 . . . . . . . . . . . . . . . . 184 060
. . . 39 . . . . . . . . . . . . . . . . 187 416
. . . 41 . . . . . . . . . . . . . . . . 192 574
. . . 41 . . . . . . . . . . . . . . . . 192 577
. . . 41 . . . . . . . . . . . . . . . . 191 562
. . . . . . . . . . . TH1 . . . . . . 188 431
. . . 42 . . . . . TE1 . . . . . . 034 587
. . . . . . . . . . . C5,6 . . . . . 111 634
. . . 43 . . . . . . . . . . . . . . . . 184 044
. . . 44 . . . . . . R3 . . . . . . 118 459
. . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, interface (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 7 SEGMENT LED DISPLAY (LED’s 18 − 23) . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . STAND-OFF, No. 6-32 x .645lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TUBING, stl .375 OD x 18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR, electlt 4000uf 100 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INSULATOR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONTROL BOX, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TRANSFORMER, high voltage 115V pri 360 OV . . . . . . . . . . . . . . . . . .
. . . SPARK GAP ASSEMBLY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BASE, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INSULATOR, bracket mtg spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR, mica .002uf 10000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR, polyp met film 10uf 250 VAC . . . . . . . . . . . . . . . . . . . . . . .
. . . RESISTOR, ww fxd 100 W 200 ohm w/clips . . . . . . . . . . . . . . . . . . . . . .
. . . RESISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . RESISTOR, ww fxd 100W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR. polyp film 150 uf 250 VAC . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, capacitor power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . RECTIFIER, si diode (Figure 8-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BUSHING, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . LIFT, eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SUPPORT, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . FAN BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . MOTOR, fan 230 V 1550 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BLADE, fan 9.000 5wg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . FAN PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BLOCK, term w/jumper link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR, clamp cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . DOOR, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . VALVE, 24 VDC 2way custom port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . .
. . . NUT, .750-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BAFFLE, panel rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONTACTOR w/BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TRANSFORMER/STABILIZER ASSEMBLY 200/230/460 . . . . . . . . . . .
. . . TRANSFORMER/STABILIZER ASSEMBLY 230/460/575 . . . . . . . . . . .
. . . TRANSFORMER/STABILIZER ASSEMBLY 220/400/440/520 . . . . . . .
. . . THERMISTER, NTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TERMIMAL ASSEMBLY, pri 1ph 3V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . RESISTOR, ww fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
6
2
1
1
1
3
1
1
1
2
1
3
3
1
1
2
1
1
1
1
4
1
1
1
1
4
1
1
1
1
5
2
1
1
1
1
1
1
2
1
1
2
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
OM-356 Page 43
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . 45 . . . . . SR2 . . . . . 035 704
. . . 46 . . . . . . F1 . . . . . . 085 874
. . . 47 . . . . . . . . . . . . . . . . 172 731
. . . 48 . . . . . . R4 . . . . . . 186 949
. . . 49 . . . . . . . . . . . . . . . . 184 061
. . . 50 . . . . . . . . . . . . . . . . 083 147
. . . 51 . . . . . . R5 . . . . . . 174 037
. . . 52 . . . . C13,14 . . . . 187 254
. . . 53 . . . . . . . . . . . . . . . . 010 381
. . . 54 . . . . . CB1 . . . . . 093 995
. . . 55 . . . . . RC2 . . . . . 189 033
. . . . . . . . . . . C12 . . . . . . 135 664
. . . 56 . . . PC4/RC2 . . . 187 445
. . . . . . . . . . PLG18 . . . . 165 484
. . . 57 . . . . . . . . . . . . . . . . 157 317
. . . 58 . . . . . . T4 . . . . . . 187 499
. . . 59 . . . . . . . . . . . . . . . . 157 318
. . . 60 . . . . . . . . . . . . . . . . 120 854
. . . 61 . . . . . . . . . . . . . . . . 184 065
. . . 62 . . . . . . . . . . . . . . . . 097 421
. . . 63 . . . . . . . . . . . . . . . . 097 922
. . . 64 . . . . . . . . . . . . . . +184 050
. . . . . . . . . . . . . . . . . . . . . . 134 327
. . . . . . . . . . . . . . . . . . . . . . 127 363
. . . 65 . . . . . . . . . . . . . . . . 169 136
. . . 66 . . . . . . . . . . . . . . . . 175 952
. . . 67 . . . . . . . . . . . . . . . . 192 547
. . . 68 . . . . . . . . . . . . . . . . 183 260
. . . 69 . . . . . . . . . . . . . . . . 191 009
. . . 70 . . . . . . S7 . . . . . . 185 196
. . . 71 . . . . . . . . . . . . . . . . 184 066
. . . 72 . . . . . . . . . . . . . . . . 174 991
. . . 73 . . . . . . . . . . . . . . . . 183 332
. . . . . . . . . . . . . . . . . . . . . . 195 778
. . . 74 . . . . . . . . . . . . . . . . 190 727
. . . . . . . . . . . . . . . . . . . . . . 183 200
. . . 75 . . . . . . . . . . . . . . . . 190 311
. . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . FUSE, mintr slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . HOLDER, fuse mintr .250 x 1.250 clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . RESISTOR, ww fxd 175W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PANEL, relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . RHEOSTAT, ww 50W 1.5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . CONNECTOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CIRCUIT BREAKER, man reset 1P 250 VAC . . . . . . . . . . . . . . . . . . . . . 1
. . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CAPACITOR, cer disc .01uf 500VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CIRCUIT CARD, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . HOLDER, HF coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . COIL, HF coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . HOLDER, HF coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . FITTING, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . LOWER HF PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . DOOR ASSEMBLY HF PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PIN, handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . RECESS, handle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . NAMEPLATE, (order by model & serial number) . . . . . . . . . . . . . . . . . . . 1
. . . PANEL, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . SWITCH, push button (Figure 8-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . DOOR, spark gap access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Rq’d
. . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Rq’d
. . . ACTUATOR, push button switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PLATE, indicator syncrowave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . BAFFLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-356 Page 44
Item
No.
...
...
...
...
...
1
2
3
4
5
Dia.
Mkgs.
Part
No.
S7
185 196
Description
. . . . . . . . . . . . . . . . 059 885
. . . . . . . . . . . . . . . . 018 606
. . . . . . . . . . . . . . . . 186 303
. . . . . . . . . . . . . . . . 081 008
. . . . . . . . . . . . . . . . 178 856
Quantity
Figure 8-2. Switch, Push Button (Fig 8-1 Item 62)
. . . BUTTON, push reset red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SPRING, compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . PUSH BUTTON, w/cable and housing . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, mtg switch PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SWITCH, limit leaf actuating SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and
1
1
1
1
1
4
not available unless listed.
3
5
2
1
ST-080 214-B
Figure 8-2. Switch, Push Button
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Rectifier, Si Diode (Fig 8-1 Item 23)
. . 1 . . . C7-10 . . . . 031 689
. . 2 . . . . . . . . . . . . . . 166 667
. . 3 . . . . . D1 . . . . . 037 956
. . 4 . . . . TH2 . . . . . 188 431
. . 5 . . SCR1-4 . . . . 115 114
. . 6 . . . . . . . . . . . . . . 173 714
. . . . . . . . . . . . . . . . . . . 028 516
. . . . . . . . PLG10 . . . . 115 092
..
..
..
..
..
..
..
..
CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, spring rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THYRISTOR, SCR 300A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, thyristor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN, spring CS .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and
4
2
1
1
4
2
2
1
3
not available unless listed.
2
4
1
2
5
5
6
ST-120 205-A
Figure 8-3. Rectifier, Si Diode
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-356 Page 45
Effective January 1, 1999
(Equipment with a serial number preface of KK" or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, 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.
Original main power rectifiers
Inverters (input and output rectifiers only)
3 Years — Parts and Labor
*
*
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
*
Motor Driven Guns (w/exception of Spoolmate
185)
*
*
Process Controllers
Positioners and Controllers
*
*
Automatic Motion Devices
Robots
*
*
RFCS Foot Controls
IHPS Power Sources
*
*
*
Water Coolant Systems
HF Units
Grids
*
*
Maxstar 140
Spot Welders
*
*
Load Banks
SDX Transformers
*
*
Miller Cyclomatic Equipment
Running Gear/Trailers
*
Plasma Cutting Torches (except APT, ZIPCUT &
PLAZCUT 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
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate 185
Miller’s True Blue Limited Warranty shall not apply to:
1.
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.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
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 7/99
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
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
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
 1999 Miller Electric Mfg. Co.
7/99
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