Miller LG470356L Owner's manual

Miller LG470356L Owner's manual
OM-2250
216 871F
2006−11
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
208/575 Volt Models W/Auto-Linet
Arc Welding Power Source
Dynasty 700
Maxstar 700
R
R
File: TIG (GTAW)
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Labels (Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Manufacturer’s Rating Labels (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power Switch . . . . . . . . . . . . .
4-7. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Remote 14 Receptacle Information (Used Without Automation Connection) . . . . . . . . . . . . . . . . . . . . .
4-9. Automation Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Remote Memory Select Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Automation Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. TIG HF Impulse/ Lift-Arct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
5
5
7
7
8
8
9
9
11
12
13
14
14
15
16
16
17
17
18
19
20
21
21
21
22
22
23
23
25
TABLE OF CONTENTS
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Polarity Control (Dynastyt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Sequencer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. AC Waveshape (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Memory (Program Storage Locations 1-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. AC Waveshape Selection (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Arc Timer/Counter Display (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Setting Unit To Display PPP While Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Stick Open-Circuit Voltage (OCV) Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . .
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
10-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
27
27
28
28
28
29
29
30
30
31
32
33
34
35
36
37
38
39
40
40
42
48
49
50
52
53
54
54
55
56
58
65
65
65
66
67
67
68
68
68
69
69
70
Declaration of Conformity for
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
Dynasty R 700
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1
dec_stat_6/05
Declaration of Conformity for
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
Maxstar R 700
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1
Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1
dec_stat_6/05
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D 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 drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand 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 in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
OM-2250 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 an approved welding helmet fitted with a proper shade of filter lenses 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,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on 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, sparks, 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.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL 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-2250 Page 2
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.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MAGNETIC FIELDS can affect pacemakers.
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, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct 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 Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
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.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
FALLING UNIT can cause injury.
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.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
OVERUSE can cause OVERHEATING
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
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
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
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
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-2250 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2250 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 before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1.
Symboles utilisés
Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints.
Y Indique un message de sécurité particulier
. Signifie NOTE ; n’est pas relatif à la sécurité.
2-2.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Dangers relatifs au soudage à l’arc
Y Les symboles représentés ci-dessous sont utilisés dans ce manuel
pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions en
matière de sécurité indiquées ci-dessous ne constituent qu’un
sommaire des instructions de sécurité plus complètes fournies
dans les normes de sécurité énumérées dans la Section 2-5. Lire et
observer toutes les normes de sécurité.
Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Y Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
D
D
D
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
D
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans
D
D
D
D
D
D
D
D
D
trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou des
tapis assez grands afin d’éviter tout contact physique avec la pièce à
couper ou le sol.
Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est
équipé.
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si l’on
porte des vêtements mouillés ; sur des structures métalliques telles que
sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC
à tension constante (à fil), 2) un poste à souder DC manuel (électrode)
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des
situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer le poste correctement et le mettre à la terre convenablement
selon les consignes du manuel de l’opérateur et les normes nationales,
provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer
que le fil de terre du cordon d’alimentation est bien raccordé à la borne
de terre du sectionneur ou que la fiche du cordon est raccordée à une
prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
D
D
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement en
place.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
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.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour la santé.
D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces vapeurs.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de
soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de
respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
portant un respirateur à alimentation d’air. Les revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
OM-2250 Page 5
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à 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 approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
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 peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections homologuées.
D Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
D Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
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 de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une longue
distance par des chemins inconnus éventuels en provoquant des
risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
D En cas de non-utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Avant de souder, retirer toute substance combustible de ses poches
telles qu’un allumeur au butane ou des allumettes.
D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un extincteur à proximité.
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-2250 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
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.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, rester
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.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
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, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de
produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
D Lire le manuel d’utilisation avant d’utiliser ou
d’intervenir sur l’appareil.
D Utiliser uniquement des pièces de rechange
Miller/Hobart.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
SUR-
D Prévoir une période de refroidissement ;
respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
D
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
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 PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
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.
D
D
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de soudage.
2-4.
D Le rayonnement haute fréquence (HF) 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 un blindage pour réduire
les interférences éventuelles.
D
D L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
D 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.
Proposition californienne 65 Avertissements
Y Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques dont
l’État de Californie reconnaît qu’ils provoquent des malformations
congénitales et, dans certains cas, des cancers. (Code de santé et
de sécurité de Californie, chapitre 25249.5 et suivants)
Pour les moteurs à essence :
Y Les gaz d’échappement des moteurs contiennent des produits
chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres problèmes de procréation.
Y Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Pour les moteurs diesel :
Y Les gaz d’échappement des moteurs diesel et certains de leurs
composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.
OM-2250 Page 7
2-5.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale
2-6.
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
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.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-2250 Page 8
1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS (CE Models Only)
3-1.
Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode
or wiring can kill.
2
2.1
2.2
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
2.3
3
1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.
3.1
1.3 Disconnect input plug or power before
working on machine.
1
1.1
2
2.1
3
3.1
3.2
1.2
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local exhaust
to remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion
or fire.
Keep flammables away from welding.
Do not weld near flammables.
Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
1.3
2.2
2.3
3.2
4
3.3 Do not weld on drums or any closed
containers.
4
Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
4.1
5
3.3
6
OM-2250 Page 9
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
2
1
2
4
3
5
3
4
5
6
7
6
9
8
7
8
9
1
2
2
1
3
4
3
4
5
5
OM-2250 Page 10
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 5 minutes after
power is turned off before
working on unit, OR
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Read the Owner’s Manual
before working on this
machine.
Disconnect input plug or
power before working on
machine.
Become trained and read the
instructions before working on
the machine or welding.
3-2.
Manufacturer’s Rating Labels (Non CE Models)
. For label location
see Section 4-5.
Manufacture’s Rating Label
For Dynasty 700 Models
223 259-D
Manufacture’s Rating Label
Maxstar 700 Models
223 275-D
OM-2250 Page 11
3-3.
Manufacturer’s Rating Labels (CE Models)
. For label location
see Section 4-5.
Manufacture’s Rating Label
For Dynasty 700 Models
223 260-C
OM-2250 Page 12
Manufacture’s Rating Label
Maxstar 700 Models
223 277-C
3-4.
Symbols And Definitions
A
Amperes
Output
V
Volts
Input
Output
Circuit Breaker
Remote
Protective Earth
(Ground)
Postflow Timer
Preflow Timer
On
Off
Positive
Alternating
Current
Gas Input
Gas Output
Duty Cycle
Direct Current
Line Connection
X
U1
U0
Primary Voltage
Rated No Load
Voltage (Average)
IP
Degree Of
Protection
Polarity Control
Remote Standard
Hz
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
3 Phase Static Frequency
Converter-Transformer-Rectifier
I1max
Rated Maximum
Supply Current
Lift-Arc (GTAW)
S
Seconds
Negative
I2
U2
I1eff
Rated Welding
Current
Conventional Load
Voltage
Maximum Effective
Supply Current
Initial Amperage
Increase/Decrease
Of Quantity
Gas/DIG Control
Percent
Hertz
Recall From
Memory
Arc Force (DIG)
Impulse Starting
(GTAW)
Final Slope
Final Amperage
Pulse Percent
On Time
Initial Slope
AC Waveshape
Control
Pulser
EP Amperage
Pulse Frequency
Work
Electrode
EN Amperage
Unit may be used
in environments
with increased
hazard of electric
shock
Sequence
Background Amperage
Process
f
AC Frequency
OM-2250 Page 13
SECTION 4 − INSTALLATION
4-1.
Specifications
A. Dynasty 700
Rated Welding Output
Input Power
Amperage
Range
500 A @ 40 Volts, 100%
Duty Cycle
Three Phase
Single
Phase
600 A @ 44 Volts, 60% Duty
Cycle
360 A @ 34 Volts, 100%
Duty Cycle
450 A @ 38 Volts DC, 60%
Duty Cycle
5−700
5−700
Maximum
Open Cir
Open-Circuit Voltage
DC
75∇
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
400 V
460 V
575 V
KVA
KW
75
68
39
34
27
27
26
97
88
51
44
35
35
34
82
74
−−
37
30
17
16
115
104
−−
52
42
24
22
10−15♦
75∇
10−15♦
*While idling
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to
any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
B. Maxstar 700
Rated Welding Output
Input Power
Amperage
Range
500 A @ 40 Volts, 100%
Duty Cycle
Three Phase
Single
Phase
600 A @ 44 Volts, 60% Duty
Cycle
360 A @ 34 Volts, 100%
Duty Cycle
450 A @ 38 Volts DC, 60%
Duty Cycle
5−700
5−700
Maximum
Open Cir
Open-Circuit Voltage
DC
75∇
Amperes Input at Rated Load Output 50/60 Hz
208 V
230 V
400 V
460 V
575 V
KVA
KW
67
60
35
30
24
24
23
89
80
46
40
32
32
31
77
70
−−
35
28
16
15
106
96
−−
48
38
22
21
10−15♦
75∇
10−15♦
*While idling
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to
any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
OM-2250 Page 14
4-2.
Volt-Ampere Curves
Maxstar 700
80
70
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
Stick Max DIG Max
60
DC Volts
50
40
20
Stick Min
10
TIG Min
0
0
90
TIG Max
80
70
100 200 300 400 500 600 700 800 900
DC Amperes
Dynasty 700 DC
80
60
50
Stick Max
60
50
TIG Min
40
30
Stick Min
20
10
0
70
DC Volts
Dynasty 700 AC
100
90
Stick Min DIG Max
AC Volts
30
TIG Max
0
100
200 300 400 500 600 700 800
AC Amperes
40
Stick Max
DIG Max
30
20
10
0
0
Stick Min DIG Max
TIG Min
TIG Max
100 200 300 400 500 600 700 800 900
DC Amperes
215 126-A / 213 342-A / 213 344-A
OM-2250 Page 15
4-3.
Duty Cycle and Overheating
Duty Cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 7-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
800
700
Y Exceeding duty cycle can
damage unit and void
warranty.
600
Output Amperes
500
3-Phase
400
1-Phase
300
200
100
0
10
20
30
40
50
60 70 80 90 100
% Duty Cycle
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
sduty1 5/95 / 213 343-B
4-4. Dimensions, Weights And Base Mounting Hole Layout
NOTE
Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
Dimensions
A
B
C
D
C
A
34-1/2 in (876 mm)
B
13-3/4 in (349 mm)
C
22 in (559 mm)
D
20-1/2 in (521 mm)
E
1 in (25 mm)
F
11-3/4 in (298 mm)
G
1/2 in Dia. (13 mm Dia.)
4 Holes
Weight
G
OM-2250 Page 16
F
E
803 914-A
198 lb (90 kg)
4-5. Selecting A Location
Y Falling Unit Can Cause Injury.
Use equipment of adequate capacity to lift
and support unit.
1
2
Movement
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to move unit.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
1
If using lifting forks, extend forks beyond opposite side of unit.
3
4
Serial Number/Patent Label
Rating Label
Use rating label to determine input power
needs (see Section 3-2).
OR
2
5
Line Disconnect Device
Locate unit near correct input power supply.
Y Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
Location And Airflow
Y Be careful when placing or moving
unit over uneven surfaces.
5
1
3
18 in (460 mm)
18 in (460 mm)
4
Ref. 117 264-C / 803 900-A / 223 259-A / 223 275-A
OM-2250 Page 17
4-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
4-7.
115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power
Switch
1
3
AC Duplex Receptacle
Receptacle RC2 supplies 115 V 10
A of single-phase power.
1
2
2
Supplementary Protector CB1
CB1 protects duplex receptacle
from overload. If circuit breaker
opens, the receptacle does not
work. Press button to reset
protector.
3
Power On/Off Switch
803 901-A
OM-2250 Page 18
4-8. 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.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding****
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amps***
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
700
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
800
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
900
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
Electrode
W k
Work
* This
10 − 100% Duty Cycle
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E−
***Select weld cable size for pulsing application at peak amperage value.
OM-2250 Page 19
4-9.
Remote 14 Receptacle Information (Used Without Automation Connection)
Socket*
A
B
K
J
A
Contactor control, 15 volts DC.
B
Contact closure to A completes 15 volts DC
contactor control circuit, and enables output.
C
+10 volts DC.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal
from remote control.
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 output
receptacle volts.
CHASSIS
K
Chassis common.
GND
G
+15 volts DC (A) common.
15 VOLTS DC
I
Socket Information
H
C L N
D M
G
E F
REMOTE
OUTPUT
CONTROL
A/V
803 900-A / 218 716-A
*The remaining sockets are not used.
Note: If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the
remote control before the Panel or Remote contactor is turned on. Failure to do so, will cause current to be controlled by the panel control and
the remote hand control will not function.
OM-2250 Page 20
4-10.
Automation Connection
2
3
7
8
14
20
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
803 900-A / 218 716-A
Pin
Pin Information For 28-Pin Receptacle RC28
1
Start/Stop - Closure to pin 8 starts the weld cycle. Opening closure stops weld cycle. During 2T operation, a momentary closure
(greater than 100 ms, but less than 3/4 seconds) starts and stops weld output.
2
Output enable - functional only in automation modes - Closure to pin 8 must be maintained at all times. If the closure between pins 2
and 8 is broken, an output disable occurs, Postflow begins to time out, and HELP 13 will be displayed on the meters.
3
Gas - Closure to pin 8 turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out
before arc initiation.
4
Valid arc, collector - Output is on when the contactor is on and there is less than 50 load volts (see Section 4-13).
5
Voltage feedback - +1 volt DC per 10 volts w/reference to pin 11.
6
Current feedback - +1 volt DC per 100 amperes w/reference to pin 11.
7
Not used
8
IGND isolation common
9
Valid arc, emitter - Output is on when the contactor is on and there is less than 50 load volts (see Section 4-13).
10
Memory enable - See Section 4-11.
11
Remote control circuit common
12
Chassis common
13
Pulse lockout, collector - Output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulsed Background
time when the pulse frequency is less than 10 Hz (see Section 4-13).
14
Pulse lockout, emitter - Output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulse Background
time, when the pulse frequency is less than 10 Hz (see Section 4-13).
15
Memory select 0 - See Section 4-11.
16
Memory select 1 - See Section 4-11.
17
Command signal from remote control - 0 to +10 volts DC input.
18
+10 volts DC
19
HF disable - Disables high frequency when connected to pin 8.
20
Automation enable 1 - See Section 4-12.
21
Amperage EN common - See Section 4-12.
22
Amperage EN command - See Section 4-12.
23
Final slope, collector - Output is on when in Final Slope (see Section 4-13).
24
Final slope, emitter - Output is on when in Final Slope (see Section 4-13).
25
Automation enable 2 - See Section 4-12.
26
Amperage EP command (Dynasty models only) - See Section 4-12.
27
Amperage EP common (Dynasty models only) - See Section 4-12.
28
Polarity (Dynasty models only) - See Section 4-12.
OM-2250 Page 21
4-11. Remote Memory Select Inputs
28-Pin Receptacle RC28
Socket Designations 0 = No Connection /
3
1
8
4
Function
10
15
16
Off
0
X
X
Memory 1
1
0
0
Memory 2
1
1
0
Memory 3
1
0
1
Memory 4
1
1
1
9
14
15
20
25
21
28
1 = Connected To Ground (Pin 8)
X= Do Not Care
26
4-12. Automation Selections
28-Pin Receptacle RC28
Socket Designations 0 = No Connection /
3
1
4
8
X= Do Not Care
9
14
1 = Connected To Ground (Pin
8)
Pin
15
20
25
Function
20
21
No automation functions selected
0
0
Automation 1
1
0
X
1
21
28
26
Enables pin 2 function, Sequencer and weld timers
Automation 2
Enables pin 2 functions
Pin 22 to pin 21 - 0 to +10 volts DC EN amplitude
Connected to pin 8 (EP)
Pin 26 to pin 27 - 0 to +10 volts DC EP amplitude
Open (EN)
Pin 28 to pin 8 - EP polarity (Frequency and Balance)
Pin 28
Pin 28 not connected to pin 8 - EN polarity (Frequency and
Balance)
Final Slope and Pulse outputs are not functional
4-13. Typical Application
CR1
R
Typical 28-Pin Output
Collector
Emitter
OM-2250 Page 22
Coil resistance plus R
should be chosen to
limit current to 75 mA
CR1
+
−
User supplied power
up to 27 volts DC peak
To User Equipment
4-14.
Gas Connections
1
Gas Fitting
Fittings have 5/8-18 right-hand
threads.
2
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
1
4
3
2
3
4
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cfh (cubic feet
per hour).
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
5/8, 1-1/8 in
803 901-A
4-15.
TIG HF Impulse/ Lift-Arct Connections
Y Turn off power before making connections.
1
Electrode Weld Output
Terminal
Connect TIG torch to electrode
weld output terminal.
2
5
Gas Out Connection
Connect torch gas hose to gas out
fitting.
3
Work Weld Output Terminal
Connect work lead to work weld
output terminal.
4
4
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 4-9).
1
5
Gas In Connection
Connect gas hose from gas supply
to gas in fitting (see Section 4-14).
Tools Needed:
2
3
11/16 in, (21 mm for CE units)
803 915-A
OM-2250 Page 23
4-16.
Stick Connections
Y Turn off power before making
connections.
. Connections shown are for
Dynasty models. For Maxstar models, reverse work and electrode connections
1
3
2
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
2
Electrode Weld Output Terminal
Connect electrode holder to electrode
weld output terminal.
3
Remote 14 Receptacle
If desired, connect remote control to Remote 14 receptacle (see Section 4-9).
1
803 916-A
4-17. Electrical Service Guide
A. Dynasty 700
NOTE
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase
Input Voltage
208
230
400
460
575
Input Amperes At Rated Output
97
88
51
44
35
Time-Delay 2
110
100
60
50
40
Normal Operating 3
150
125
80
70
50
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
4
4
8
8
10
118
(36)
144
(44)
177
(54)
235
(72)
240
(73)
6
6
8
8
10
Single-Phase
Input Voltage
208
230
460
575
Input Amperes At Rated Output
115
104
52
42
Time-Delay 2
125
125
60
50
Normal Operating 3
175
150
80
60
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
3
4
8
8
107
(33)
107
(33)
178
(54)
279
(85)
6
6
8
10
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-2250 Page 24
B. Maxstar 700
NOTE
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase
Input Voltage
208
230
400
460
575
Input Amperes At Rated Output
89
80
46
40
32
Time-Delay 2
110
100
50
50
40
Normal Operating 3
125
125
70
60
50
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
4
6
8
8
10
129
(39)
101
(31)
194
(59)
257
(78)
263
(80)
6
6
8
10
10
Single-Phase
Input Voltage
208
230
460
575
Input Amperes At Rated Output
106
96
48
38
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2
125
110
50
45
Normal Operating 3
150
150
70
60
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
4
4
8
10
94
(29)
115
(35)
189
(58)
194
(59)
6
6
8
10
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-2250 Page 25
4-18.
Connecting Input Power
A. Connecting Three-Phase Input Power
5
6
Y Installation must meet all National
and Local Codes − have only qualified
persons make this installation.
Y Disconnect and lockout/tagout input
power before connecting input conductors from unit.
Y Make input power connections to the
welding power source first.
Y Always connect green or green/yellow conductor to supply grounding
terminal first, and never to a line terminal.
4
See rating label on unit and check input voltage available at site (see Section 4-5).
2
1
1
Select size and length of conductors using
Section 4-17. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
3
Welding Power Source Input Power Connections
3
8
Input Power Conductors (Customer
Supplied Cord)
= GND/PE Earth Ground
10
7
2
Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
3
4
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source grounding terminal first.
5
9
6
4
6
Welding Power Source Line Terminals
(Switch S1)
Input Conductors L1 (U), L2 (V) And L3
(W)
Connect input conductors L1 (U), L2 (V) and
L3 (W) to welding power source line
terminals.
Install cover.
Disconnect Device Input Power Connections
7
8
Disconnect Device (switch shown in
OFF position)
Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
9
Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protection using Section 4-17 (fused disconnect
switch shown).
Tools Needed:
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
803 927-A
OM-2250 Page 26
B. Connecting Single-Phase Input Power
6
5
Y Installation must meet all National
and Local Codes − have only qualified persons make this installation.
Y Disconnect and lockout/tagout input power before connecting input
conductors from unit.
2
Y Make input power connections to
the welding power source first.
Y Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4
2
See rating label on unit and check input
voltage available at site (see Section 4-5).
1
1
1
Select size and length of conductors using
Section 4-17. Conductors must comply
with national, state, and local electrical
codes. If applicable, use lugs of proper
amperage capacity and correct hole size.
3
8
Input Power Conductors (Customer
Supplied Cord)
=GND/PE Earth Ground
Welding Power Source Input Power
Connections
2
Strain Relief
Route conductors (cord) through strain relief and tighten screws.
10
7
3
4
Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source
grounding terminal first.
9
6
4
5
6
Welding Power Source Line
Terminals (Switch S1)
Input Conductors L1 (U) And L2 (V)
Connect input conductors L1 (U) And L2
(V) to welding power source line terminals.
Install cover.
Disconnect Device
Connections
7
8
Input
Power
Disconnect Device (switch shown in
OFF position)
Disconnect Device (Supply)
Grounding Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
9
Disconnect Device Line Terminals
Connect input conductors L1 (U) And L2
(V) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 4-17 (fused disconnect switch shown).
Tools Needed:
Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
803 927-B
OM-2250 Page 27
SECTION 5 − OPERATION
5-1.
Controls
2
1
3
11
12
f
4*
5
8
7
6
9
10*
213 320-A / 803 901-A
*Available On Dynasty Models Only.
13
Rear Panel
. For all front panel switch pad controls:
4
Polarity Control (Dynasty Only)
See Section 5-12.
press switch pad to turn on light and enable normal function.
See Section 5-6.
10 AC Waveshape (Dynasty Only)
5
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a normal Stick function.
See Section 5-13.
See Section 5-7.
1
Encoder Control
2
Ammeter And Parameter Display
See Section 5-4.
3
Voltmeter
See Section 5-5.
OM-2250 Page 28
6
Process Controls
Output Controls
See Section 5-9.
7
Pulser Controls
11 Amperage And Spot Time Control
For Amperage Control see Section 5-3.
For Spot Time Control see Section 5-14.
See Section 5-10.
12 Memory
8
See Section 5-15.
Sequencer Controls
See Section 5-11.
13 Power Switch
9
Use switch to turn unit On/Off.
Gas/DIG Controls
5-2.
Encoder Control
1
1
5-3.
Amperage Control
1
2
3
3
2
1
5-4.
Encoder Control
Use control in conjunction with applicable front panel function switch
pad to set values for that function.
A (Amperage Control)
Encoder Control
Ammeter
See Section 5-16 for Amperage
control range.
Press Amperage switch pad, and
turn Encoder control to set weld
amperage, or peak amperage
when Pulser function is active (see
Section 5-10).
Note: See Section 5-13 for AC functions.
Ammeter And Parameter Display
1
1
Ammeter
Ammeter displays actual amperage while welding. It also displays
preset parameters for any of the following: amperage, time, percentage or frequency. The LED located
directly below the ammeter will also
illuminate.
OM-2250 Page 29
5-5.
Voltmeter
1
1
5-6.
Volt Meter
Displays output or open circuit voltage. If output is off, the voltmeter will
display (-−−).
Polarity Control (Dynastyt Models Only)
1
Polarity Control
Press switch pad until desired LED
is illuminated.
DC - Set machine to DCEN for TIG
welding, and to DCEP for Stick
welding.
AC - Use AC for TIG and Stick
welding.
1
OM-2250 Page 30
5-7.
Process Control
1
Process Control
Press switch pad until desired process LED is illuminated:
TIG HF Impulse - is a pulsed HF
(see Section 5-8) arc starting method that can be used with either AC
or DC TIG welding. Make connections according to Section 4-15.
TIG Lift-Arct - is an arc starting
method in which the electrode must
come in contact with the workpiece
(see Section 5-8). This method can
be used with either AC or DC TIG
welding. Make connections according to Section 4-15.
1
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections according to Section 4-16.
5-8. Lift-Arc™ And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control.
Hold electrode to workpiece for
1-2 seconds, and slowly lift electrode. Arc is formed when electrode
is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to start arc
when output is enabled. High frequency turns off when arc is
started, and turns on whenever arc
is broken to help restart arc.
Application:
HF start is used for the DCEN
GTAW process when a non-contact arc starting method is required.
OM-2250 Page 31
5-9.
Output Control
2
1
1
Output Control
Press switch pad until desired parameter
LED is illuminated.
RMT STD (Remote Standard)
Application: Use Remote Trigger (Standard) with a foot pedal or finger amperage
control (see Section 6-2A).
NOTE: When a foot or finger remote current control is connected, initial amps, initial slope, final slope, and final amps are
controlled by the remote control.
OM-2250 Page 32
NOTE: If an On/Off type trigger is used, it
must be a maintained switch. All Sequencer functions become active, and must be
set by the operator.
NOTE: This switch function can be reconfigured for 3T, 4T, 4T Momentary, Mini Logic, or Spot control See Section 6-2C)
RMT 2T HOLD
Output will energize two seconds after being selected.
Application: Use Remote Trigger Hold
(2T) for long extended welds.
If a foot or finger current control is connected to the welding power source, only
trigger input is functional (see Section
6-2B).
ON
Application: Use Output On for Stick
(SMAW) welding, or for Lift-Arc without the
use of a remote control (see Section 6-2I).
2
On LED
Blue On LED is lit whenever Output is on.
5-10.
Pulser Control
1
3
2
Pulser Control
Pulsing is available while using the
TIG process. Controls can be adjusted while welding.
Press switch pad to enable pulser.
ON - When illuminated, this LED indicates the pulser is on.
Press switch pad until desired parameter LED is illuminated.
To turn Pulser off, press and release
switch pad until the On LED turns off.
2
3
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 5-16 for all Pulser parameter ranges.
PPS Pulses Per Second or (Pulse
Frequency) Used to determine appearance of weld bead.
PEAK t - The percentage of each
pulse cycle at the peak amperage
level.
1
BKGND A (Background Amps) - Use
Background Amps to set the low
pulse of the weld amperage, which
cools the weld puddle and affects
overall heat input. Background Amps
is a percentage of peak amperage.
4
4
Percent (%) Peak
Time Control Setting
Balanced
More Time
At Peak
Amperage
More Time
At
Background
Amperage
Pulsed Output Waveforms
PPS
(50%)
Bkg Amp
Peak Amp
(80%)
Pulsed Output Waveforms
Example shows affect changing the
Peak Time control has on the pulsed
output waveform.
NOTE: Peak amperage is set using
the Amperage control (see Section
5-3). Peak amperage is the highest
welding amperage allowed in the
pulse cycle. Weld penetration varies
directly with peak amperage.
Application:
Pulsing is 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 better control of
penetration, bead width, crowning,
undercutting, and heat input.
(20%)
OM-2250 Page 33
5-11.
Sequencer Controls
1
Sequencer Control
Sequencing is available while using
the TIG process, but is disabled if a
remote foot or finger current control
is connected to the Remote receptacle while in the RMT STD mode.
3
2
Press switch pad until desired parameter LED is illuminated.
2
3
4
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 5-16 for all Sequencer
parameter ranges.
INITIAL A (Initial Amperage) - Use
control to select a starting amperage that is different from the weld
amperage.
Application:
Initial Amperage can be used to assist in preheating cold material prior
to depositing filler material, or to ensure a soft start.
1
INITIAL t (Initial Time)(Available
with Automation option Only) Press control again and turn Encoder to set amount of time needed
at the beginning of the weld.
INITIAL SLOPE t (Initial Slope
Time) Use control to set amount of
time that it takes to slope from initial
amperage to weld amperage. To
disable, set to 0.
4
Amperage Switch Pad
Weld Time (Available with Automation option Only) - Press
Amperage switch pad twice. Set
desired weld time.
FINAL SLOPE t (Final Slope Time)
- Use control to set amount of time
it takes to slope from weld amperage to final amperage. To disable,
set to 0.
Application:
Final Slope should be used while
welding materials that are crack
sensitive, and/or to eliminate the
crater at the end of the weld.
FINAL A (Final Amperage) - Used
to set amperage to which weld amperage slopes to.
FINAL t (Final Time)(Available
with Automation option Only) Press control again and turn Encoder to set Final Amperage time.
OM-2250 Page 34
5-12.
Gas/DIG Controls (Preflow/Post Flow/DIG/Purge)
1
Gas/DIG Controls
Press switch pad until desired function
LED is illuminated.
3
2
3
2
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 5-16 for all Adjust parameter
ranges.
PREFLOW - If the TIG HF process is active (see Section 5-7) and Preflow is
shown on the control panel, use control to
set length of time gas flows before arc initiation.
Application: Preflow is used to purge
the weld area and aids in arc starts.
POST FLOW - If the TIG process is active (see Section 5-7), use control to set
length of time gas flows after welding
stops.
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.
. Some features shown are
not available on all models.
1
DIG - If the DC Stick process is active
(see Section 5-7), use control to set
amount of DIG. When set at 0, short-circuit amperage at low arc voltage is the
same as normal welding amperage.
When setting is increased, short-circuit
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.
PURGE - To activate the gas valve and
start the purge function, push and hold
the Gas/DIG switch pad for the desired
amount of time. To set from 1 to 50 seconds of purge time, hold the Gas/DIG
switch pad while turning the encoder control. Default is 0.
While Purge is active, (Pur) is shown in
the left display, and purge time is shown
in the right display.
Pressing any switch pad will end the
purge display, but gas will continue to flow
until the preset time has timed out.
Application: Purge is used to clear the
gas lines.
OM-2250 Page 35
5-13.
AC Waveshape (Dynasty Models Only)
1
3
AC Waveshape Control
Press switch pad until desired function LED is
illuminated.
2
3
2
Encoder Control (Set Value)
Ammeter (Displays Value)
See Section 5-16 for all AC Waveshape parameter ranges.
Balance: AC Balance control is enabled only
in AC TIG to set percentage of time polarity is
electrode negative.
4
Application:
When welding on oxide forming materials such
as aluminum or magnesium, excess cleaning
is not necessary. To produce a good weld, only
0.10 in (2.5mm) of etched zone along the weld
toes is required.
Use AC Balance to control the etch zone width.
Joint configuration, set-up, process variables,
and oxide thickness may affect setting.
AC Frequency: AC Frequency control is enabled only in AC TIG. Use control to set AC frequency (cycles per second).
Application:
f
1
AC Frequency controls arc width and directional control. As AC frequency decreases, the arc
becomes wider and less focused, limiting directional control. As AC frequency increases,
the arc becomes narrower and more focused,
increasing directional control. Travel speed
can increase as AC frequency increases.
EN Amperage: Use control to select electrode
negative amperage value.
EP Amperage: Use control to select electrode
positive amperage value.
EN Amperage and EP Amperage allow the operator the ability to control the amount of amperage in the negative and positive half cycles
independently. A 2 to 1 or 3 to 1 ratio of EN to
EP is a good starting point. This provides
cleaning action, but directs more energy into
the workpiece and provides faster travel
speeds and deeper penetration.
4
Amperage Control
Average Amperage Control: Setting EN Amperage, EP Amperage, Balance, and Frequency values creates an average amperage. The
operator can change the average amperage
value while maintaining the same EN amperage to EP amperage ratio at the existing balance and frequency. To change the average
amperage value, press the Amperage switch
pad and turn the Encoder control. The changing average value is displayed on the ammeter.
Example: If EN Amperage is 300, EP Amperage is 150, Balance is 60%, and Frequency is
120, the average amperage is 240 amps. If you
press the Amperage switch pad and turn the
Encoder control until 480 amps is displayed,
the EN amperage is now 600 and EP amperage is now 300. The balance remains 60%, and
the frequency is still 120, and the 2 to 1 EN amperage to EP amperage is maintained.
OM-2250 Page 36
5-14.
Spot Time Control (Reconfigured RMT 2T HOLD Output Selection)
1
1
SPO
Spot Time Meter Display
Select Spot function according to
Section 6-2C.
3
2
3
1.0
2
Amperage Switch Pad
Encoder Control
To set spot parameters, press Amperage switch pad once (meter A
LED turns on) and turn Encoder to set
spot amperage. Press Amperage
switch pad again, (meter S LED
lights) and turn Encoder to set spot
time (.1−25 seconds). Default is 1
second.
Application: To provide a timed weld
for tacking and thin sheet joining.
OM-2250 Page 37
5-15.
Memory (Program Storage Locations 1-4)
1
2
3
Memory (Program Storage
1-4) Switch Pad
Polarity Switch Pad (Dynasty
Only)
Process Switch Pad
To create, change, or recall a
welding parameters program,
proceed as follows:
1
First, press Memory switch pad until
the desired program storage location (1-4) LED is illuminated
Second, press Polarity switch pad
until the desired polarity, AC or DC,
LED is illuminated
1st
f
2*
Third, press Process switch pad until desired process, TIG HF Impulse,
TIG Lift Arc, or Stick, LED is illuminated.
The program at the chosen location,
for the desired polarity and process,
is now the active program.
2nd
Fourth, change or set all desired parameters (see Section 5-1 for parameters).
3rd
3
. Some features shown are
*Available On Dynasty Models Only.
not available on all models.
TIG (HF or Lift)
AC
And
Stick
Memory Locations
1−4
And
TIG (HF or Lift)
DC
And
Stick
Each memory location (1 thru 4) can store parameters for both
polarities, and each polarity can store parameters for both process (TIG or Stick) for a total of 16 programs.
OM-2250 Page 38
5-16.
Factory Parameter Defaults And Range And Resolution
Parameter
Default
MEMORY
1
Range And Resolution
1−4
*POLARITY
AC
AC / DC
PROCESS
TIG HF Impulse
TIG HF Impulse / TIG Lift / Stick
OUTPUT
RMT STD
RMT STD / RMT 2T / ON
**RMT 2T
2T
RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic
/ 4T Momentary / Spot (see Section 6-2C)
A MAIN / PEAK
*AC TIG
500 A
5 − 700 Amps
*AC STICK
110 A
5 − 700 Amps
DC TIG
500 A
5 − 700 Amps
DC STICK
110 A
5 − 700 Amps
Spot Time
1.0 S
0.1 − 25.0 Seconds
***Weld Time
0S
Dual Range And Resolution
0.0 − 99.9 / 100 − 999 Seconds
PULSER
Off
ON / OFF
PPS
100 Hz
Quad Range And Resolution
DC: 0.1 − 9.9 / 10 − 500 / 510 − 990 / 1K − 5K Hertz
AC: 0.1 − 9.9 / 10 − 500 Hertz
PEAK t
40%
5 − 95 Percent
BKGND A
25%
5 − 95 Percent
INITIAL A
20 A
5 − 700 Amps
SEQUENCER
***Initial Time
0 S
0.0 − 25.0 Seconds
INITIAL SLOPE t
0S
0.0 − 25.0 Seconds
FINAL SLOPE t
0S
0.0 − 25.0 Seconds
FINAL A
5A
5 − 700 Amps
***Final Time
0S
0.0 − 25.0 Seconds
ADJUST
PREFLOW
0.2 S
0.0 − 25.0 Seconds
POST FLOW
10.0 S
0.0 − 50.0 Seconds @ 0.2 Second Resolution
DIG
30%
0 − 100 Percent
Waveform
Soft Square
Soft Square, Advanced Square, Sine, Triangle
EN Amps
500A
5 - 700 Amps
EP Amps
500A
5 - 700 Amps
BALANCE
75%
30 − 99 Percent
FREQUENCY
120 Hz
20 − 400 Hertz
*AC WAVESHAPE
**Impulse HF Start parameters for each program (1-4)
MAXSTAR:
Amperage
30 A
5 − 700 Amps
Time
3 mS
1 − 200 Milliseconds
EN
EP / EN
*DYNASTY:
DC:
Polarity
Amperage
30 A
5 − 700 Amps
Time
3 mS
1 − 200 Milliseconds
AC:
Polarity
Amperage
Time
EP
EP / EN
40 A
5 − 700 Amps
40 mS
1 − 200 Milliseconds
* DYNASTY parameter selection only
** Parameter adjusted using a power up configuration only
*** Parameter used with the automation option only
OM-2250 Page 39
5-17.
Resetting Unit To Factory Default Settings
1
2
3
4
Process Switch Pad
Output Switch Pad
Gas/DIG Switch Pad
Power Switch
To reset all welding power source
functions to original factory settings,
lockout feature must be off (see Section 6-5). Turn power on and then
press and hold the Process, Output,
and Gas/DIG switch pads before the
software version clears the meters.
f
4
1
2
3
V
Rear Panel
OM-2250 Page 40
SECTION 6 − ADVANCED FUNCTIONS
6-1.
A.
Programmable TIG Start Parameters
Accessing Programmable TIG Start Parameters (All Models)
4
2
f
5*
1
6
3
And
V
*Available On Dynasty Models Only.
Rear Panel
NOTE: The welding cycle can be executed
while in programmable start mode. Before
accessing programmable TIG Start Polarity, Amperage, and Time modes, be sure
that all procedures and parameters are established.
1 Process Switch Pad
2 Amperage Switch Pad
3 Power Switch
To access the programmable TIG Start
Amperage and Time screens, turn power
on, and then press the Process and Amperage switch pads before the software version clears the meters. Hold switch pads
until software version clears the meters
and [SEL] [EP] or [SEL] [EN] appears.
4
Memory Switch Pad
Press Memory switch pad to select desired
memory location (see Section 5-15).
5
Polarity Switch Pad (Dynasty Models
only)
Press Polarity switch pad to select AC or
DC (see Section 5-6).
Note: Each memory location and each polarity (AC or DC) has its own set of start
parameters.
Press the Process switch pad to select the
desired process, TIG HF Impulse or TIG
Lift Arc, for your application (see Section
5-7). The parameter values are the same
for both processes, and any changes made
to the values in one process, are duplicated
in the other process.
6
Output Switch Pad
Press Output switch pad to select desired
type of control (see Section 5-9).
Proceed to Section B, C and/or D.
To save changes and exit Advanced Functions, turn power off.
OM-2250 Page 41
B.
Changing Programmable TIG Start Polarity (Dynasty Models Only)
3
2
E−
SEL
1
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
C.
To adjust TIG Start Polarity, press Amperage switch pad. Switch pad LED turns on,
and meter % LED turns on. The current
Start Polarity, SEL] [E−] or [SEL] [EP] is dis-
played on meters, and can be changed
(see Section 5-16) by turning the Encoder
control.
Changing Programmable TIG Start Amperage
3
2
20
SEL
1
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
To adjust TIG Start Amperage, press Amperage switch pad. Switch pad LED turns
on, and meter A LED turns on. The current
Start Amperage is displayed on the amps
meter, and can be adjusted (see Section
5-16) by turning the Encoder control.
D. Changing Programmable Start Time
3
SEL
2
10
1
1
2
3
Amperage Switch Pad
Encoder Control
Amps Meter
OM-2250 Page 42
To adjust Programmable Start Time, press
Amperage switch pad, and meter S LED
turns on. The current Start Time is dis-
played on the amps meter, and can be adjusted by turning the Encoder control (see
Section 5-16).
6-2.
Output Control And Trigger Functions
A. Remote (Standard) Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P/H
R
Maintained Switch
R
Foot Or Finger
Remote Control
P/H = Push trigger and hold
R = Release trigger.
NOTE: When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope
and final amps are controlled by the remote control.
B. Remote 2T Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P/R
P/R
P/R = Push trigger and release. NOTE: If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
OM-2250 Page 43
C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control
4
H−2
SEL
1
2
And
3
V
Rear Panel
For RMT STD (Remote Standard), RMT 2T
Hold (Remote 2T Hold), and On trigger operation, see Section 6-2A, B, and I.
1
Process Switch Pad
2
Output Switch Pad
3
Power Switch
OM-2250 Page 44
To access the RMT 2T HOLD, turn power
switch on, press and hold the Process and
Output switch pads before the software
version clears the meters and [SEL] appears. RMT 2T Hold LED will light.
4
Encoder Control (Set Value)
5
Ammeter (Displays Value)
H-2 = 2T (see Section 6-2B)
SPO = Spot (see Section 6-2H)
H-3 = 3T (see Section 6-2D)
H-4 = 4T (see Section 6-2E)
H4L = Mini Logic (see Section 6-2F)
H4E = 4T Momentary (see Section 6-2G).
Press torch trigger or turn power Off to
save setting.
D.
3T Specific Trigger Method
1
SEL
H-3
Current (A)
Remote Trigger Operation
*
*
*
A
Preflow
*
*
*
*
B
Initial Amps /Initial Slope
C
Main Amps
D
Final Slope /Final Amps
E
Postflow
* Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc.
1 3T (Specific Trigger Operation)
Sequencer is required to reconfigure for 3T.
3T requires a specific type of remote control with two independent momentarycontact switches. One will be designated
initial switch, and it must be connected between Remote 14 receptacle pins A and B.
The second will be designated as the final
switch, and it must be connected between
Remote 14 receptacle pins D and E.
Select 3T according to Section 6-2C.
Definitions:
Initial slope rate is the rate of amperage
change determined by the initial amperage,
initial slope time, and main amperage.
Final slope rate is the rate of amperage
change determined by the main amperage, final slope time, and final amperage.
Operation:
A..Press and release initial switch within 3/4
second to start shielding gas flow. To stop
the preflow sequence before preflow time
elapses (25 seconds), press and release
final switch. The preflow timer will reset
and the weld sequence can be started
again.
. If an initial switch closure is not made
again before preflow time ends, gas flow
stops, the timer resets, and an initial
switch press and release is necessary to
start the weld sequence again.
B..Press initial switch to start arc at initial
amps. Holding switch will change amperage at initial slope rate (release switch to
weld at desired amperage level).
C..When main amperage level is reached,
initial switch can be released.
D..Press and hold the final switch to decrease amperage at final slope rate (release switch to weld at desired amperage
level).
E.. When final amperage has been reached,
the arc extinguishes and shielding gas
flows for the time set on the Postflow control.
Application:
With the use of two remote switches instead
of potentiometers, 3T gives the operator the
ability to infinitely increase, decrease, or
pause and hold amperage within the range
determined by the initial, main, and final amperages.
OM-2250 Page 45
E. 4T Specific Trigger Method
1
1
4T (Specific Trigger Operation)
Select 4T according to Section 6-2C.
Torch trigger operation is as shown.
SEL
H−4
4T allows the operator to toggle between weld current and final
current.
= 4T
NOTE: When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source.
Application:
Use 4T trigger method when the functions of a remote current
control are desired, but only a remote on/off control is available.
Current (A)
Torch Trigger Operation
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P/H
R
P/R
P/R
P/H
R
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
F. Mini Logic Operation
1
1
Mini Logic Meter Display
Select Mini Logic according to Section 6-2C.
SEL
Torch trigger operation is as shown.
H4L
=
Mini Logic
Mini logic allows the operator to toggle between initial slope
or main amps and initial amps. Final Amperage is not available. Final slope will always slope to minimum amperage
and end the cycle.
NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Application: This ability to change current levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc.
Torch Trigger Operation
Main Amps
Final Slope
Initial Slope
*
Initial Amps
Preflow
P/H
R
*
*
*
P/R
P/R
P/R
P/R
Postflow
P/R
P/H
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
* = Arc can be extinguished at final slope rate at any time by pushing and holding trigger
OM-2250 Page 46
G. 4T Momentary Operation
1
1
4T Momentary Meter Display
Select 4T Momentary according to Section 6-2C.
SEL
4T Momentary torch trigger operation is as shown.
H4E
= 4T Momentary Main
NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Application:
Use 4T Momentary trigger method when the functions of a
remote current control are desired, but only a remote on/off
control is available.
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
*
Final Amps
Postflow
Preflow
P/R
P/R
P/R
P/R
P/R
P/R = Push and release trigger; * = Push and releasing during final slope will break the arc and go to postflow
NOTE: For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends
H. Spot Control Operation
1
1
Spot Function Meter Display
Select Spot function according to Section 6-2C.
See Section 5-14 for operation.
SEL
SPO
=
NOTE: While in Spot Control, Sequencer settings are not be
programmable.
Spot
NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Torch trigger operation is as shown.
Application: Used for tacking and thin sheet joining.
Current (A)
Timed Spot Weld Amps
Preflow
P/H
Postflow
R
P/H = Push and hold trigger; R = Release Trigger
OM-2250 Page 47
I.
On Trigger Operation
Voltage (V)
ON
2 Sec
Current (A)
Stick
Touch Stick
Electrode
Lift Stick
Electrode
Current (A)
Lift
Main Amperage
Initial Amperage
Initial Slope
Touch Current
Touch Tungsten
OM-2250 Page 48
Lift Tungsten
Slightly
Lift Tungsten
6-3.
AC Waveshape Selection (Dynasty Models Only)
SEL
4
5
SS
f
2
1
3
And
V
Rear Panel
= Soft Squarewave
= Advanced Squarewave
= Sine wave
1
Polarity Switch Pad
2
AC Waveshape Switch Pad
3
Power Switch
To access the AC Waveshape selection
screen, turn power on, and then press the
Polarity and Waveshape switch pads before the software version clears the meters
and [SEL] [ssq) appears. The active Memory
LED, AC LED, and the EN and EP Amperage LED’s will light.
4
Memory Switch Pad
= Triangular wave
Each memory location can select any of
four wave shapes.
5
Encoder
Use the Encoder, at any of the four memory
locations, to select between advanced
squarewave [ASq], soft squarewave [ssq]
(default), sine wave (Sin), or triangle wave
(Tri).
To save changes and exit, press torch trigger or turn power off.
Note: During normal operation, when EN or
EP Amperage is selected, the left parame-
ter screen will display the active waveshape (ASq), (SSq), (Sin), or (tri) as a reminder.
Application: Use advance squarewave
when a more focused arc is required for
better directional control. Use soft squarewave when a softer arc with a more fluid
puddle is desired. Use sine wave to simulate a conventional power source. Use
triangular waveshape when the effects of
peak amperage with reduced overall heat
input is required to help control distortion on
thin materials.
OM-2250 Page 49
6-4.
Arc Timer/Counter Display (All Models)
3/4
123
456
Or
1
f
1
2
And
V
Rear Panel
1
2
Output And Amperage Controls
Power Switch
To display the arc timer/counter, turn power
switch on, press and hold the Amperage
Control and Output switch pads until the
software version clears the meters.
OM-2250 Page 50
3 Arc Timer Display
The meter S LED will turn on, and arc time
will be displayed for 5 seconds as [000 000
] to [999 959 ]. The first four numbers indicate
hours, and the last two numbers indicate
minutes. Example shown is read as 1,234
hours and 56 minutes. Maximum arc time is
9,999 hours and 59 minutes.
4
Arc Counter
After 5 seconds, the meter A LED turns on,
and the arc counter will be displayed for the
next 5 seconds as [000 000 ] to [999 999 ].
The maximum arc cycle count is 999 999.
6-5.
Lockout Functions
A. Accessing Lockout Capability
4
5
L−−
000
1
6
And
000
LL!
2
2, 3, or 4
3
V
Rear Panel
See Section 5-1 for explanation of controls referred to in all of
Section 6-5.
Toggle Amperage (A) switch pad to light the meter S LED. You may
now select a lockout level.
There are four (1−4) different lockout levels. Each successive level
allows the operator more flexibility.
There are four lockout levels available. Turn Encoder control to select a lockout level (see Sections 6-5B for lockout level descriptions).
NOTE: Before activating lockout levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lockout levels are active.
1 Amperage (A) Switch Pad
2 Gas/DIG Switch Pad
3 Power Switch
To access lockout screens, turn On power switch, and then before
the software version clears the meters, push and hold the Amperage
and Gas/DIG switch pads until software version number clears meters.
4 Lockout Off
Upon power up as described, the meter % and Amperage (A) switch
pad LED’s light, and the meter display will be as shown for a lockout
off condition.
5 Encoder Control
To turn On the lockout feature, proceed as follows:
6
Pressing Amperage (A) switch pad will toggle between the meter %
and S LED’s. Toggle switch pad until % LED is on.
Turn Encoder control to select a three digit lockout number. Number
will appear on the voltage (left) meter. Select any number from [001]
thru [999 ]. IMPORTANT: remember this three digit number, as you
will need it to turn the lockout feature off.
Lockout On
Once the desired three digits have been entered and a lockout level
selected, press torch trigger or turn Off power to complete lockout on
sequence.
NOTE: Setting a three digit lockout number of [000], or setting a lockout level of [L−−] will cause a lockout off condition.
To turn Off the lockout feature, proceed as follows:
To access lockout screens, turn On power switch, and then before
the software version clears the meters push and hold the Amperage
and Gas/DIG switch pads until software version number clears meters.
Upon power up as described, the meter % and Amperage (A) switch
pad LED’s will turn on, and the meter display will be as shown for a
lockout on (see callout 6) condition.
Use Encoder control to enter the same three digits that were used
to turn on the lockout feature.
Press the Amperage (A) switch pad. The meter % LED will turn off,
and the S LED will light. The amperage (right) meter display will
change to [L−−]. The lockout feature is now off.
Press torch trigger or turn Off power to complete lock out Off
sequence.
OM-2250 Page 51
B. Lockout Levels
Levels 1, 2, And 3
L3
Use Encoder Control To Adjust
Amperage +/− 10% Of Preset
Value.
L2
Press switch pads in the
hand combinations shown to
access the different lockout
levels, L1, L2, or L3.
L2
L2
L1
L3
Level 4
A
B
K
J
I
H
C L N
D M
G
E F
NOTE: Before activating lock out levels, be
sure that all procedures and parameters are
established. Parameter adjustment is limited while lock out levels are active.
Level 1
NOTE: Remote amperage control is not
available in level 1.
TIG Output Selection
If either the TIG HF Impulse or TIG Lift Arc
process (see Section 5-7) was active when
lockout level 1 was activated, the operator
can choose between RMT STD (Remote
Standard) or RMT 2T HOLD (Remote 2T
Hold) (see Section 5-9). The On function is
also available if TIG Lift Arc was active.
When parameter change or selection is limited by lock level 1, [L-1 ] is displayed as a
reminder.
Level 2
NOTE: Remote amperage control is not
available in level 2.
Includes all the functions of level 1 plus
Memory, Polarity and Process Selection
(see Sections 5-6 and 5-7).
When parameter change or selection is limited by lock level 2, [L-2] is displayed as a reminder.
Level 3
If RMT 2T HOLD was reconfigured (see
Section 6-2C) prior to lockout level 1 activation, the reconfigured output mode (4T, 4T
momentary, mini logic, or spot) is available
to the operator instead of RMT 2T.
NOTE: Remote amperage control is not
available in level 3.
Stick Output Selection
+/− 10% adjustment of preset TIG or
Stick Weld Amps
If the Stick process was active when lockout level 1 was activated, the operator can
choose between RMT STD or On.
OM-2250 Page 52
Includes all the functions of levels 1 and 2
plus the following:
Select desired process, TIG or Stick, and
use Encoder control to adjust amperage +/−
10% of preset amperage value, up to the
limits of the machine. If operator tries to go
beyond the +/− 10%, the amperage (right)
meter will display [L-3 ] as a reminder.
Pulser ON/Off Control
Gives operator the ability to turn on/off the
Pulser control.
When parameter change or selection is limited by lock level 3, [L-3] is displayed as a reminder.
Level 4
Includes all the functions of levels 1, 2, and
3 plus the following:
Remote Amperage Control
Allows operator to use remote amperage
control if desired. Remote control operates
from minimum to maximum of preset amperage value. Connect remote control device according to Section 4-9.
When parameter change or selection is limited by lock level 4, [L-4] is displayed as a reminder.
6-6. Setting Unit To Display PPP While Pulse Welding
5
PPP
4
sel
−−−
2
1
And
3
V
Rear Panel
1 Output Switch Pad
2 Pulser Switch Pad
3 Power Switch
To access the PPP while welding display,
turn power switch on, press and hold the
Output and Pulser switch pads until software version clears meters and [SEL] appears. A and Pulser On LED’s will light.
4
Encoder Control
5
PPP Meter Display
Turn Encoder to change between standard
and (PPP) meter display.
When the (PPP) meter display feature is active while pulse welding, (PPP) is displayed,
and the meter hold feature is disabled.
The (PPP) meter display feature will not effect the normal amperage display or Meter
Hold capabilities when in a non-pulse
welding mode.
Press torch trigger or turn off power to save
setting.
OM-2250 Page 53
6-7. Stick Open-Circuit Voltage (OCV) Selection
5
6
loc
sel
3
1
2
4
And
V
Rear Panel
1
Process Switch Pad
2
Gas/DIG Switch Pad
3
4
Amperage Switch Pad
Power Switch
To access the Stick OCV selection, turn
power switch on and then press the Process, Gas/DIG and Amperage switch pads
before the software version clears the me-
OM-2250 Page 54
ters. Hold the switch pads until [SEL] [Loc] or
[SEL] [noc) appears.
5
Encoder Control
6
Meter Display
Turn Encoder to change between low OCV
[SEL] [Loc] and normal OCV [SEL] [noc]. Active
selection is displayed on the meters.
When Stick low OCV is selected, open-circuit voltage is between 9 and 14 volts.
When Stick normal OCV is selected, opencircuit voltage is approximately 80 volts.
Application: For most Stick applications
use low open-circuit voltage. Use normal
open-circuit voltage for hard to start Stick
electrodes, or if required for your particular
application.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
unreadable
labels.
Replace damaged
gas hose.
Clean and
tighten weld
terminals.
Repair or replace cracked
cables and cords.
6 Months
Blow out inside. During heavy
service, clean monthly.
7-2. Blowing Out Inside of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
803 900-A
OM-2250 Page 55
7-3. Voltmeter/Ammeter Help Displays
1
V
A
HE.L
P30
1
30 Series Display
Top Module
. All directions are
in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
1
Typical Voltmeter/Ammeter Help
Display
A 30 series message refers to the top power
source, and a 40 series message refers to
the bottom power source. Only one series
message (30 or 40) will be displayed at a
time
w Help 30/40 Display
Indicates a failure in the thermal protection
circuitry located in the input inductor of the
unit. Contact a Factory Authorized Service
Agent if this display is shown.
w Help 31/41 Display
Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this display is shown.
w Help 32/42 Display
Indicates a failure in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
w Help 33/43 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation
will continue when the unit has cooled.
OM-2250 Page 56
V
A
HE.L
P40
40 Series Display
Bottom Module
w Help 34/44 Display
Indicates a failure in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
w Help 13 Display (Automation Models
Only)
Output disable open causing weld output to
stop, but gas continues to flow.
w Help 35/45 Display
w Help 14 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation
will continue when the unit has cooled.
Unit not ready. Primary circuit bus not up to
full power.
w Help 6 Display
Indicates that the input voltage is too low
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have an
electrician check the input voltage if this display is shown.
w Help 7 Display
Indicates that the input voltage is too high
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have an
electrician check the input voltage if this display is shown.
w Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. There is a high
open circuit condition. Contact a Factory
Authorized Service Agent if this display is
shown.
w Help 39/49 Display
Indicates the input inductor of the unit has
overheated. Contact a Factory Authorized
Service Agent if this display is shown.
w Help 10 Display
Indicates torch trigger is depressed. Release trigger to continue.
w Help 12 Display
Indicates a non-allowable set-up on the
front panel.
w Help 15 Display
Indicates a primary overpower condition.
Output current is decreased to limit primary
power draw. Depress any switch pad and
turn encoder or strike an arc to clear the last
help condition.
w Help 16 Display
Secondary clamp voltage too high.
w Help 20 Display
Indicates that the power supplies for the primary drives have failed. Contact a Factory
Authorized Service Agent if this display is
shown.
w
Help 21 Display
Indicates voltage or current feedback has
been detected with contactor off. Contact a
Factory Authorized Service Agent if this
display is shown.
w
Help 22 Display
Voltage and current not present with contactor on. Contact a Factory Authorized
Service Agent if this display is shown.
w
Help 24 Display
Indicates a power supplies for the control
and interface board PC6 failure.
7-4. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-18).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-18).
Check for proper input power connections (see Section 4-18).
No weld output; meter display On.
If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Sections 5-1 and 4-9).
Input voltage outside acceptable range of variation (see Section 4-17).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-8).
Clean and tighten all weld and gas connections.
No 115 volts ac output at duplex receptacle.
Reset circuit breaker CB1 (see Section 4-7).
Fan not operating. Note: Fan only runs
when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc
Use proper size tungsten (see Section 10-1).
Use properly prepared tungsten (see Section 10-2).
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
weld
Increase postflow time (see Section 5-12).
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
OM-2250 Page 57
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram For Dynasty 700 Models (Part 1 of 2)
OM-2250 Page 58
213 338-C
OM-2250 Page 59
213 338-C
Figure 8-2. Circuit Diagram For Dynasty 700 Models (Part 2 of 2)
OM-2250 Page 60
Notes
OM-2250 Page 61
Figure 8-3. Circuit Diagram For Maxstar 700 Models (Part 1 of 2)
OM-2250 Page 62
215 121-C
OM-2250 Page 63
215 121-C
Figure 8-4. Circuit Diagram For Maxstar 700 Models (Part 2 of 2)
OM-2250 Page 64
SECTION 9 − HIGH FREQUENCY
9-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 12/96 − S-0693
9-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-2250 Page 65
9-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
OM-2250 Page 66
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Metal Building Requirements
9
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install
copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
7
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
11 Overhead Door Track
Ground the track.
SECTION 10 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2004
Y Whenever possible and practical, use DC weld output instead of AC weld output.
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode
Negative/Straight Polarity
DC − Argon − Electrode Positive/Reverse Polarity
AC − Argon
AC − Argon −
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
Balanced Wave
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium
(Red Band) Alloy Tungstens
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
1/8”
250-400
25-40
225-360
160-250
5/32”
400-500
40-55
300-450
200-320
3/16”
500-750
55-80
400-500
290-390
1/4”
750-1000
80-125
600-800
340-525
.010”
*
*
Up to 15
Up to 10
.020”
*
*
5-20
10-20
.040”
*
*
10-60
20-30
1/16”
*
10-20
50-100
30-80
3/32”
*
15-30
100-160
60-130
1/8”
*
25-40
150-210
100-180
5/32”
*
40-55
200-275
160-240
3/16”
*
55-80
250-350
190-300
1/4”
*
80-125
325-450
250-400
.010”
*
*
Up to 20
Up to 15
.020”
*
*
15-35
5-20
.040”
*
*
20-80
20-60
1/16”
*
*
50-150
60-120
3/32”
*
*
130-250
100-180
1/8”
*
*
225-360
160-250
5/32”
*
*
300-450
200-320
3/16”
*
*
400-550
290-390
1/4”
*
*
600-800
340-525
Pure Tungsten
(Green Band)
Zirconium Alloyed Tungsten (Brown
Band)
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
OM-2250 Page 67
10-2. Preparing Tungsten Electrode For Welding
Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
2-1/2 Times
Electrode Diameter
Radial Grinding
Causes Wandering Arc
1
3
2
1
2
3
Tungsten Electrode
Flat
Diameter of this flat determines amperage
capacity.
4
Wrong Tungsten Preparation
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
Ideal Tungsten Preparation − Stable Arc
4
Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For Conventional AC Welding
1 − 1-1/2 Times
Electrode Diameter
1
2
1
2
Tungsten Electrode
Balled End
Ball end of tungsten by applying AC amperage recommended for a given electrode
diameter (see Section 10-1). Let ball on end
of the tungsten take its own shape.
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)
11-1. Positioning The Torch
Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work
clamp as close to the weld as possible.
. For additional information, see your distributor for a handbook on the
3
Gas Tungsten Arc Welding (GTAW) process.
2
1
Workpiece
Make sure workpiece is clean before welding.
4
2
Work Clamp
Place as close to the weld as possible.
1
4
3
4
5
6
90°
10−15°
Select and prepare tungsten according to Sections 10-1 and 10-2.
5
6
10−25°
5 6
Guidelines:
The inside diameter of the gas cup should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in diameter, gas cup should be a minimum of
3/16 in diameter.
Tungsten extension is the distance the tungsten extends out gas cup of
torch.
1/16 in
The tungsten extension should be no greater than the inside diameter of
the gas cup.
3/16 in
Arc length is the distance from the tungsten to the workpiece.
Bottom View Of Gas Cup
OM-2250 Page 68
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Ref. ST-161 892
11-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
15°
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
11-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
10°
15°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
15°
30°
ST-162 003 / S-0792
OM-2250 Page 69
SECTION 12 − PARTS LIST
. Hardware is common and
not available unless listed.
6
12
5
4
11
13
14 15
9
10
7 8
16
33
2
1
3
8
25
35
24
36
26
27
34
38
23
28
37
18
29
17
22
21
38
22 21 19
20
8
30
37
31
3
32
18
1
28
Dynasty 700 illustrated
804 133-C
Figure 12-1. Main Assembly
OM-2250 Page 70
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . . 1 . . . . . . . . . . 223 785
. . . 1 . . . . . . . . . . 223 784
. . . 2 . . . . . . . . . . 213 071
. . . 3 . . . . . . . . . +213 057
. . . 4 . . . . . . . . . . 213 056
. . . 5 . . . . . . . . . . 203 990
. . . 5 . . . . . . . . . . 179 310
. . . 6 . . . . . . . . . . 213 073
. . . 7 PC18,PC8 207 157
. . . 8 . . . . . . . . . . 080 509
. . . 9 . . . . . . . . . . 221 708
. . . 10 . . . . . . . . . . 010 493
. . . 11 . . . . . . . . . +213 058
. . . 12 . . . . T2 . . 213 059
. . . 13 . . . . . . . . . . 155 436
. . . 14 . . . . . . . . . . 218 170
. . . 15 . . . . . . . . . . 089 120
. . . 16 . . . . . . . Figure 12-3
. . . 17 . . . . . . . Figure 12-5
. . . 18 . . . . . . . Figure 12-4
. . . 19 . . . PC7 . . 214 712
. . . . . . . . . . . . . . . . 189 786
. . . . . . . . . . . . . . . . 196 455
. . . 20 . . . . . . . . . . 213 055
. . . 21 . . . . . . . . . . 213 074
. . . 22 . . . HD1 . . 182 918
. . . 23 . . . . . . . Figure 12-7
. . . 23 . . . . . . . Figure 12-8
. . . 24 . . . . . . . . . . 213 248
. . . 25 . . . PC5 . . 221 722
. . . 26 . . . . . . . . . . 215 402
. . . 27 . . . . . . . . . . 057 357
. . . 28 . . . . . . . Figure 12-6
. . . 29 . . C6,C7 . 222 752
. . . 30 . . . . . . . . . . 221 721
. . . 31 . . . . C8 . . 221 707
. . . 32 . . . . . . . Figure 12-2
. . . . . . . . . . . . . . . . 215 120
. . . 33 . . PC19 . 187 264
. . . 34 . . . . . . . . . . 222 760
. . . 35 . . . . . . . . . . 226 878
. . . 36 . . . . . . . . . . 195 666
. . . 37 . RT5, RT6 231 292
. . . 38 . . . C11 . . 231 486
. . LABEL, SIDE DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, SIDE MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . .
. . LABEL, GENERAL PRECAUTIONARY WORDLESS CE . . . . . . . . . . . . . . . . .
. . SEAL, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, SCR NO 8/10 PANEL HOLE .312 SQ .375 HIGH . . . . . . . . . . . .
. . BRACKET, MTG PC BOARD (DYNASTY 700 MODELS ONLY) . . . . . . . . . . .
. . BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
. . LIFT EYE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . XFMR, 665 115/24 18/18 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, NPRN BRD NO 1 X .250 ID X 25.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, HOSE .375 − .450 CLP DIA SLFTTNG GREEN . . . . . . . . . . . . . . . . .
. . PANEL, REAR W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, PRIMARY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WINDTUNNEL, RIGHT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, HF (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTACT, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POINT, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, LEM 23 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSDUCER,CURRENT 400A MODULE SUPPLY V +/− 15V . . . . . . . . .
. . HEAT SINK, SECONDARY − DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, SECONDARY − MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LUG, UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, AUX POWER W/PROGRAM . . . . . . . . . . . . . . . . . . . .
. . PANEL, TOP WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING,SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . .
. . WINDTUNNEL, LEFT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, WINDTUNNEL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, FRONT W/CMPNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTION KIT, DINSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, FILTER (CE MODELS ONLY) . . . . . . . . . . . . . . . . . . .
. . BRACKET, FILTER BOARD (CE MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, HARNESS SUPPORT (MAXSTAR 700 MODELS ONLY) . . . . . .
. . SCREW, 010−32X .50 TORX PANHD W/GNDRNG STL PLD . . . . . . . . . . . .
. . THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN W/HEAT SHRINK . . . . . .
. . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
1
1
1
1
2
9
1
2
1
1
1
1
2
1
2
2
1
2
2
1
2
2
2
2
1
1
1
1
2
1
1
1
1
1
1
1
1
2
2
2
+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-2250 Page 71
. Hardware is common and
13
not available unless listed.
14
12
9
10
11
15
6
8
19 18
17
16
20
2
3
4
7
5
1
804 138-A
Figure 12-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
221 408
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
8
9
10
11
12
12
13
14
15
16
17
18
19
20
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
. . . PC6 . .
. . . RC1 . .
..........
..........
..........
..........
..........
FMB,FMT
213 053
214 826
186 228
185 712
202 552
213 051
216 859
213 069
213 518
174 991
215 294
212 490
213 320
215 119
220 755
213 327
185 717
178 548
185 714
185 718
185 713
213 072
Quantity
Figure 12-2. Panel, Front w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
PANEL, LOUVER COVER (ORDER SERIAL NO. CARD ALSO) . . . . . . . . . .
RECEPTACLE, THREAD LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, GAS(FEMALE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, FRONT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, INDICATOR FRONT − DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, INDICATOR FRONT − MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . .
BUSHING, FLG 375−32X.511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE/SWITCH MEMBRANE, DYNASTY 350/700 STH/FF . . . . . . . .
NAMEPLATE/SWITCH MEMBRANE, MAXSTAR 350/700 STH/FF . . . . . . . .
CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . . . . .
RECEPTACLE, W/LEADS & PLUG 14PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL, CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN . . . . . . . . .
O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN, MUFFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
3
3
1
1
1
1
1
1
1
1
1
1
1
1
3
1
3
3
3
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 72
9
. Hardware is common and
not available unless listed.
5
6
8
7
10
4
3
2
11
1
804 139-A
Figure 12-3. Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
221 409
. . . 1 . . . . . . . . . +213 054
. . . 2 . . . GS1 . . 216 607
. . . 3 . . . CB1 . . 183 492
. . . 4 . . . RC2 . . 189 033
. . . 5 . . . . . . . . . . 115 516
. . . 6 . . . . . . . . . . 010 467
. . . 7 . . . . . . . . . . 137 761
. . . 8 . . . . . . . . . . 215 117
. . . 9 . . . . . . . . . . 217 297
. . . 10 . . . . . . . . . . 221 164
. . . 10 . . . . . . . . . . 219 842
. . . 11 . . . . S1 . . 221 124
. . . . . . . . . . . . . . . . 213 060
Description
Quantity
Figure 12-3. Panel, Rear w/Components
. . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . . . . .
. . SUPPLEMENTARY PROTECTOR, MAN RESET 1P 10A 250V FRIC . . . . .
. . RCPT, STR DX GND 2P3W 15A 125V (GRAY) . . . . . . . . . . . . . . . . . . . . . . . . .
. . RIVET, AL .187 DIA X .063−.125 GRIP BLK BLIND DOME . . . . . . . . . . . . . . .
. . CONN, CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE, IDENT REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, RECEPTACLE WEATHERPROOF DUPLEX RCPT . . . . . . . . . . . . .
. . LABEL, WARNING ELECTRIC SHOCK/INPUT POWER CONNECT . . . . . .
. . LABEL, WARNING INPUT CONNECTIONS/ELECTRIC SHOCK CE . . . . . .
. . SWITCH, TGL ASSY (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, TGL 3 PST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
+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-2250 Page 73
. Hardware is common and
not available unless listed.
1
2
3
4
5
6
7
8
14
13
11
12
9
10
804 134-A
Figure 12-4. Wind Tunnel, Right Hand w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
213 345
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
4
5
6
7
8
9
10
11
11
12
13
14
. . . . L1 . . 213 350
. . . . T3 . . 213 326
. . . . T4 . . 215140
. . . . . . . . . +212 489
. . . . . . . . . . 195 666
. . . . . . . . . . 216 861
. . . . . . . . . . 170 647
. . . . . . . . . . 216 860
. . C4,C20 217 941
. . . . . . . . . . 207 418
. . . . C3 . . 216 700
. . . . . . . . . . 218 004
. . . . . . . . . . 219 844
. . . . . . . . . . 010 493
. . . . . . . . . . 218 566
. . . . L2 . . 213 348
Quantity
Figure 12-4. Wind Tunnel, Right Hand w/Components
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
INDUCTOR, INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, COUPLING (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, COUPLING (BOTTOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 010−32X .50 TORX PANHD WGNDRNG STL PLD . . . . . . . . . . . . .
STAND−OFF, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
GROMMET, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, ELCTLT 1800 UF 500 VDC CAN 2.52 DIA . . . . . . . . . . . . . . . . .
SCREW, K40X 20 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . .
CAPACITOR, POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS CE . . . . . . . .
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
GASKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, INDUCTOR (PRE−REGULATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
3
2
1
2
2
2
1
1
1
1
1
1
+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-2250 Page 74
1
. Hardware is common and
not available unless listed.
2
3
4
5
6
7
5
804 135-A
Figure 12-5. Heat Sink, Primary Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
219 344
...
...
...
...
...
...
...
1
2
3
4
5
6
7
..........
. . . RM1 .
..........
. RT1,RT3
. MOD1,2
. PC1,PC2
..........
213 346
205 751
207 451
213 353
217 625
220 759
200 565
Quantity
Figure 12-5. Heat Sink, Primary Assembly
..
..
..
..
..
..
..
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODULE, POWER RESISTOR W/PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, 008−32X .50 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
KIT, INPUT/PRE−REGULATOR AND INVERTER MODULE . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, POWER INTERCONNECT . . . . . . . . . . . . . . . . . . . . .
SCREW, M 5− .8X 35 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . .
1
1
3
1
1
1
4
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-2250 Page 75
3
4
5
2
. Hardware is common and
not available unless listed.
6
1
10
11
7
9
8
804 136-B
Figure 12-6. Wind Tunnel, Left Hand w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
213 354
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
3
4
5
6
7
8
9
10
11
. . . . . . . . . . 170 647
. . . . . . . . . . 218 004
. . . . . . . . . . 219 844
. . . CR1 . . 206 258
. . . . . . . . . . 145 217
. . . . . . . . . +212 488
. . . . T1 . . 213 361
. . . . Z4 . . 213 513
. . . . Z1 . . 213 356
. . . . . . . . . . 010 493
. . . . . . . . . . 010 381
. . . . . . . . . . 227 746
Figure 12-6. Wind Tunnel, Left Hand w/Components
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . .
LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS CE . . . . . . . . .
RELAY, ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . . . . . . . . . . .
SCREW, K40X 12 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . .
PANEL, LEFT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT INDUCTOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . .
CONNECTOR, RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, INDUCTOR MOUNTING E55 FERRITE CORE . . . . . . . . . . . . . . .
2
1
1
1
2
1
1
1
1
3
1
1
+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-2250 Page 76
. Hardware is common and
7
not available unless listed.
6
4
5
3
2
1
8
9
10
804 137-A
Figure 12-7. Heat Sink, Secondary − Dynasty 700
Item
No.
Dia.
Mkgs.
Part
No.
Description
219 345
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
. PC3,PC4
..........
..........
. PM1 − 6
. . D1,D2 .
. RT2,RT4
..........
. . . SR1 . .
..........
. . . PC9 . .
222 753
213 517
216 867
213 522
213 521
213 353
213 346
201 530
216 868
220987
Quantity
Figure 12-7. Heat Sink, Secondary − Dynasty 700
..
..
..
..
..
..
..
..
..
..
CIRCUIT CARD ASSY, COMMUTATOR CONTROL . . . . . . . . . . . . . . . . . . . . .
BUS BAR, OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, POSITIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, IGBT (CONSISTS OF 3 IGBT’S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, NEGATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSEMBLY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
2
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 77
. Hardware is common and
not available unless listed.
804 177-A
Figure 12-8. Heat Sink, Secondary − Maxstar 700
Item
No.
Dia.
Mkgs.
Part
No.
Description
221 730
...
...
...
...
...
...
1
2
3
4
5
6
..........
. . D1, D2
. . . SR1 . .
. RT2, RT4
. . . PC3 . .
..........
213 346
213 521
201 531
213 353
220 987
213 519
Quantity
Figure 12-8. Heat Sink, Secondary − Maxstar 700
..
..
..
..
..
..
HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 78
Effective January 1, 2006
(Equipment with a serial number preface of “LG” 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
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
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 2006−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2006 Miller Electric Mfg. Co. 2006−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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