Miller SYNCROWAVE 210 Owner's Manual

OM-261726L

TIG (GTAW) Welding

Stick (SMAW) Welding

Description

2020-06

For product information,

Owner’s Manual translations, and more, visit

www.MillerWelds.com

File: TIG (GTAW)

From Miller to You

Thank you

and

congratulations

on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety Precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller, you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is, and our extensive service network is there to help fix the problem.

Warranty and maintenance information for your particular model are also provided.

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System

Standard.

Working as hard as you do

− every power source from

Miller is backed by the most hassle-free warranty in the business.

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_Thank1 2020 − 01

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Hazards For Installation, Operation, And Maintenance

1-4. California Proposition 65 Warnings

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards

1-6. EMF Information

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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

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2-6. Informations relatives aux CEM

SECTION 3 − DEFINITIONS

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3-1. Additional Safety Symbols And Definitions

3-2. Miscellaneous Symbols And Definitions

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SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Dimensions And Weights

4-7. Duty Cycle Chart

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4-8. Environmental Specifications

4-9. Static Characteristics

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SECTION 5 − INSTALLATION

5-1. Selecting A Location

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5-2. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Weld Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Removing Power Pin Style Connector To Adapt Spoolmate 100/150 Models For Use With

The Syncrowave 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Installing Dinse Style Connector To Adapt Spoolmate 100/150 Models For Use With

The Syncrowave 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Adapter Cord Connections To Adapt Spoolmate 100/150 Models For Use With The

Syncrowave 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Input Power Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Connecting 115 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Connecting 1-Phase 230 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Multi − Voltage Plug (MVP) Connection

SECTION 6 − OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6-1. Syncrowave 210 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Accessing Control Panel Menu: AC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Accessing DC TIG Control Panel Menu

6-4. Accessing DC Stick Control Panel Menu

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6-5. Accessing Spool Gun Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Accessing User Setup Menu: AC And DC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Accessing User DC Stick Setup Menu

6-8. Accessing User Spool Gun Setup Menu

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SECTION 7 − ADVANCED MENU FUNCTIONS

7-1. Accessing Tech Menu

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SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance

8-2. Circuit Breaker CB1

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8-3. Meter Troubleshooting Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING

WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . .

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-2. Electrode And Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-3. Striking An Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-4. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-5. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-6. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-7. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-8. Electrode Movement During Welding

13-9. Welding Lap Joints

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13-10.

Welding Groove (Butt) Joints

13-11.

Welding T-Joints

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13-12.

Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-13.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

COMPLETE PARTS LIST − Available at www.MillerWelds.com

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som 2020 − 02

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

.

Indicates special instructions.

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE

− Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid these hazards.

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information

found in the Principal Safety Standards listed in Section 1-5.

Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

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 weld output in damp, wet, or confined spaces, 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, ground, and operate 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 Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

D Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or repaired 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

Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.

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. Disconnect cable for process not in use.

D Use GFCI protection when operating auxiliary equipment in damp or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.

D Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.

D Allow cooling period before working on equipment.

D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

OM-261726 Page 1

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

Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.

D Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

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.

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 from arc rays and sparks 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 body protection made from durable, flame − resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

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 cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

D Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see

Safety Standards).

D Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline).

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 body protection made from durable, flame − resistant material

(leather, heavy cotton, wool). Body protection includes oil-free clothing 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

After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or bypass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

D

Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT 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.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.

D Always ventilate confined spaces or use approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is high.

OM-261726 Page 2

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

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 compressed 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. Do not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in use or connected for use.

D Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport 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 Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

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.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

D

Use correct procedures and equipment of adequate capacity to lift and support unit.

D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94 − 110) when manually lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

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.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

D

Sparks can cause fires — keep flammables away.

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.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive rolls.

WELDING WIRE can injure.

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.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.

MOVING PARTS can injure.

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 and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

D Use only genuine replacement parts from the manufacturer.

D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and local codes.

OM-261726 Page 3

H.F. RADIATION can cause interference.

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.

D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

D

If notified by the FCC about interference, stop using the equipment at once.

D Have the installation regularly checked and maintained.

D 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.

1-4. California Proposition 65 Warnings

WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.

For more information, go to www.P65Warnings.ca.gov.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,

American Welding

Society standard ANSI Standard Z49.1. Website: www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1 from American National Standards Institute.

Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting,

American Welding Society Standard AWS F4.1 from Global Engineering Documents. Website: www.global.ihs.com.

Safe Practices for Welding and Cutting Containers that have Held Combustibles,

American Welding Society Standard AWS A6.0 from Global

Engineering Documents. Website: www.global.ihs.com.

National Electrical Code,

NFPA Standard 70 from National Fire Protection

Association. Website: www.nfpa.org and www. sparky.org.

Safe Handling of Compressed Gases in Cylinders,

CGA Pamphlet P-1 from Compressed Gas Association. Website:www.cganet.com.

1-6. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers − by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

ARC WELDING can cause interference.

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.

D To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive electronic equipment.

D Be sure this welding machine is installed and grounded according to this manual.

D 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.


CSA Standard

W117.2 from Canadian Standards Association.

Website: www.csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work,

NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA

Occupational Safety and Health Standards for General Industry

,

Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part

1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.

OSHA

Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation

from the

National Institute for Occupational Safety and Health (NIOSH).

Website: www.cdc.gov/NIOSH.

4. Keep head and trunk as far away from the equipment in the welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recommended.

OM-261726 Page 4

7

SECTION 2 −

CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

som_2020 − 02_fre

Pour écarter les risques de blessure pour vous − même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

.

Indique des instructions spécifiques.

DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

AVIS

− Indique des déclarations pas en relation avec des blessures personnelles.

2-2. Dangers relatifs au soudage à l’arc

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES

CHAUDES. Reportez − vous aux symboles et aux directives ci − dessous afin de connaître les mesures à prendre pour éviter tout danger.

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 consignes de sécurité présentées ci − après ne font que résumer les informations contenues dans les principales normes de

sécurité énumérées à la section 2-5. Lire et observer toutes les

normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec succès sa capacité à résoudre les problèmes liés à la tâche, le travail ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.

Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.

Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.

D Ne pas toucher aux pièces électriques sous tension.

D Porter des gants isolants et des vêtements de protection secs et sans trous.

D 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.

D Ne pas utiliser de sortie de soudage CA dans des zones humides ou confinées ou s’il y a un risque de chute.

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D 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 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 !

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D

En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez − les contre les étincelles et les pièces métalliques chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé − , le remplacer immédiatement s’il l’est − . Un fil dénudé peut entraîner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.

D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.

D Ne pas enrouler les câbles autour du corps.

D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.

D

Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.

D S’assurer que tous les panneaux et couvercles sont correctement en place.

D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.

D

Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.

D Éteignez l’unité, débranchez le courant électrique, et déchargez les condensateurs d’alimentation selon les instructions indiquées dans le manuel avant de toucher les pièces.

OM-261726 Page 5

LES PIÈCES CHAUDES peuvent provoquer des brûlures.

D

Ne pas toucher à mains nues les parties chaudes.

D Prévoir une période de refroidissement avant de travailler à l’équipement.

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 FUMÉES ET LES GAZ peuvent

être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer les fumées.

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. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquelles est exposé le personnel.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.

D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

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.

LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets e 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 pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1

et Z87.1 énuméré dans les normes de sécurité).

D Porter des 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 un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent

être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

OM-261726 Page 6

D

Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D

Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et de 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 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.

D Ne pas couper ou souder des jantes ou des roues. Les pneus peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les normes de sécurité.

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 et AWS A6.0

(voir les Normes de Sécurité).

D Ne pas souder là où l ’ air ambiant pourrait contenir des poussières, gaz ou émanations inflammables (vapeur d ’ essence, par exemple).

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 porte-

électrode ou couper le fil à la pointe de contact.

D

Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.

D

Une fois le travail achevé, assurez − vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.

D

Utiliser exclusivement des fusibles ou coupe − circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DES

SALETES peuvent provoquer des blessures dans 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.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz comprimé 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.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

D

Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.

D

Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

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 comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne.

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 Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter 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.

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.

LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

D Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter 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.

D Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

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.

LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et les yeux.

D Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent causer des blessures.

D Ne pas s’approcher des organes mobiles.

D Ne pas s’approcher des points de coincement tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la 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.

L’EXPLOSION DE LA BATTERIE peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent causer des blessures.

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 Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.

OM-261726 Page 7

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.

Lire les informations de sécurité au début du manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de provoquer des interférences.

D

Effectuer régulièrement le contrôle et l’entretien de l’installation.

D

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 Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio − navigation et de communication, les services de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.

2-4. Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de provoquer des interférences.

D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement

électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

D

Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.

D

Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

D Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.

D 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.

AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de

Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

2-5. Principales normes de sécurité


American Welding

Society standard ANSI Standard Z49.1. Website: www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1 from American National Standards Institute.

Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting,

American Welding Society Standard AWS F4.1 from Global Engineering Documents. Website: www.global.ihs.com.

Safe Practices for Welding and Cutting Containers that have Held Combustibles,

American Welding Society Standard AWS A6.0 from Global

Engineering Documents. Website: www.global.ihs.com.

National Electrical Code,

NFPA Standard 70 from National Fire Protection

Association. Website: www.nfpa.org and www. sparky.org.

Safe Handling of Compressed Gases in Cylinders,

CGA Pamphlet P-1 from Compressed Gas Association. Website:www.cganet.com.

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs

électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les


CSA Standard

W117.2 from Canadian Standards Association.

Website: www.csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work,

NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA

Occupational Safety and Health Standards for General Industry

,

Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part

1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.

OSHA

Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation

from the

National Institute for Occupational Safety and Health (NIOSH).

Website: www.cdc.gov/NIOSH.

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

OM-261726 Page 8

.

A complete Parts List is available at www.MillerWelds.com

SECTION 3

−

DEFINITIONS

3-1. Additional Safety Symbols And Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Do not move or operate unit where it could tip.

3-2. Miscellaneous Symbols And Definitions

A

V

Amperes

Volts

U

1

Primary Voltage

Line Connection

Remote

Protective Earth

(Ground)

On

U

2

Conventional

Load Voltage

U

0

Rated No Load

Voltage (OCV)

IP

Degree Of

Protection

I

2

Off

Alternating

Current

Rated Welding

Current

X

Duty Cycle

I

1max

I

1eff

Rated Maximum

Supply Current

Maximum

Effective Supply

Current

Hz

Hertz

Percent

Safe1 2012 − 05

Safe 113 2017 − 04

S

Output

Suitable For

Areas Of

Increased Shock

Hazard

Alternating

Current (AC) And

Direct Current

(DC)

Direct Current

(DC)

Gas Tungsten Arc

Welding (GTAW)

Shielded Metal

Arc Welding

(SMAW)

U p

Rated Peak

Voltage

Inverter Power

Source With

AC/DC Output

OM-261726 Page 9

.


SECTION 4

−

SPECIFICATIONS

4-1. Included with Your Unit

4

3

5

6

7

9

1. 12 ft (3.7 m) Work Cable

With Clamp And

Quick-Connect

2. WP1712SFDI 150 Amp

TIG Torch with 12 ft (3.7 m)

Cable And Quick-Connect

3. Electrode Holder and

Quick-Connect

4. Gas Hose

5. Gas Regulator

6. Power Cable Adapter

7. Cable/Torch Hanger

8. Foot Pedal Holder

9. RFCS-14 Foot Control with

20 ft (6 m) Cable

.

Some assembly is required.

For options and accessories see back of book or contact your distributor.

8

2

1

805522-A

4-2. Serial Number And Rating Label Location

The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-3. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at https://www.millerwelds.com/eula and are incorporated by reference herein.

4-4. Information About Default Weld Parameters And Settings

NOTICE

− Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose.

OM-261726 Page 10

.


4-5. Specifications

.

Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-8, 5-10 and/or 5-11 for information

on connecting input power.

.

This equipment will deliver rated output at an ambient air temperature up to 104

5

F (40

5

C).

Input

Power

Process

Welding

Amperage

Range

Max. OCV

115 VAC

DC TIG

AC TIG

Stick

5 − 125

5 - 114

20 − 90

Rated Output

75 A at 13 V, 100% Duty Cycle

95 A at 13.8 V, 60% Duty Cycle








Amps Input At

Rated Output

13.2 (.58)*

17.4 (.58)*

25.2 (.58)*

10.4 (.58)*

12.4 (.58)*

18.3 (.58)*

15.6 (.58)*

20.5 (.58)*

25.9 (.58)*

KVA

1.54 (.07)*

2.05 (.07)*

3.04 (.07)*

1.20 (.07)*

1.43 (.07)*

2.11 (.07)*

1.84 (.07)*

2.47 (.07)*

3.14 (.07)*

KW

1.46 (.02)*

1.94 (.02)*

2.79 (.02)*

1.12 (.02)*

1.33 (.02)*

1.98 (.02)*

1.74 (.02)*

2.30 (.02)*

2.87 (.02)*

47 VDC

230 VAC

DC TIG

AC TIG

Stick

5 − 210

5 - 184

20 -150












( )* While idling.

4-6. Dimensions And Weights

8.4 (.35)*

11.9 (.35)*

14.7 (.35)*

23.6 (.35)*

6.6 (.35)*

8.62 (.35)*

12.1 (.35)*

16.6 (.35)*

7.9 (.35)*

11.9 (.35)*

21.8 (.35)*

1.96 (.08)*

2.72 (.08)*

3.43 (.08)*

5.56 (.08)*

1.53 (.08)*

1.99 (.08)*

2.80 (.08)*

3.84 (.08)*

1.84 (.08)*

2.79 (.08)*

5.12 (.08)*

1.84 (.02)*

2.61 (.02)*

3.31 (.02)*

5.35 (.02)*

1.44 (.02)*

1.91 (.02)*

2.69 (.02)*

3.77 (.02)*

1.72 (.02)*

2.68 (.02)*

4.94 (.02)*

47 VDC

Dimensions

B

A

C

A 31-1/2 in. (800 mm)

B 18-1/2 in. (470 mm)

805519-A

C 43 in. (1092 mm)

Weight

134 lb (60.8 kg)

OM-261726 Page 11

.


4-7. Duty Cycle Chart

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

220

210

200

190

180

170

160

10

TIG - 230 VAC

Stick - 230 VAC

TIG - 115 VAC

Stick - 115 VAC

100

50

% DUTY CYCLE

40% Duty Cycle at 150 A AC/DC

Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

NOTICE

− Exceeding duty cycle can damage unit and void warranty.

4 Minutes Welding 6 Minutes Resting

260380-A

4-8. Environmental Specifications

A. IP Rating

IP Rating

IP23S

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.

IP23S 2014 − 06

B. Temperature Specifications

Operating Temperature Range

14 to 104

°

F ( − 10 to 40

°

C)

*Output is derated at temperatures above 104 ° F (40 ° C).

Storage/Transportation Temperature Range

− 22 to 131 ° F ( − 30 to 55 ° C)

Temp_2016- 07

4-9. Static Characteristics

The static (output) characteristics of the welding power source can be described as

drooping

during the SMAW and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.

OM-261726 Page 12

.


SECTION 5

−

INSTALLATION

5-1. Selecting A Location

Movement

!

Do not move or operate unit where it could tip.

Location And Airflow

18 in. (460 mm)

18 in. (460 mm)

1

18 in. (460 mm)

!

Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC

Section 20.

1. Line Disconnect Device

2. Running Gear

Locate unit near correct input power supply.

For information about sources of

high-frequency see Section 10.

2

18 in. (460 mm) loc_cart mount 2015-08

OM-261726 Page 13

.


5-2. Remote 14 Receptacle

Socket* Socket Information

B

A

K

J

I

C L N

D M

E

F

G

H

A

E

G

I

J

C

D

A

B

K

15 volts DC.

Contact closure to A completes 15 volts DC contactor control circuit.

Command reference; 0 to +10 volts DC output to remote control.

Remote control circuit common.

0 to +10 volts DC input command signal from remote control.

Spool gun motor common.

Spool gun motor, +3.5 to 15 VDC.

Spool gun detect, 0 VDC when spool gun is connected, +3.3

VDC with no spool gun attached.

Chassis common.

*The remaining sockets are not used.

Notes

OM-261726 Page 14

.


5-3. Shielding Gas Connections

Tools Needed:

5/8, 1-1/8 in.

3

2

1

.

Use argon shielding gas for best performance.

1. Cylinder Valve

Open valve slightly so gas flow blows dirt from valve. Close valve.

2. Regulator/Flow Gauge

Connect regulator/flow gauge to gas cylinder. Do not over tighten.

Connect gas hose to gas in fitting.

3. Flow Adjust

Typical flow rate is 20 cfh (cubic feet per hour).

5-4. Weld Output Connections

OR

OR

2

3

1

Ref. 805519-A

1. Electrode Output Terminal

For Stick (SMAW) connect electrode holder to this terminal.

For TIG (GTAW), connect torch to this terminal.

For MIG (GMAW) connect spool gun to this terminal.

2. Work Terminal

Connect work clamp to this terminal.

3. Process Selector

Use control to select weld process

(see Section 6-1).

805521-A

OM-261726 Page 15

.


5-5. Removing Power Pin Style Connector To Adapt Spoolmate 100/150 Models For Use

With The Syncrowave 210

1

3

2

!

Turn Off welding power source and disconnect spool gun.

Photo 1 − Power Pin Style Connector

Power pin style connector that comes standard with the spool gun must be changed to a Dinse style connector for use with the Syncrowave 210.

1. Strain relief

Turn strain relief cap 1/4 turn counter clockwise, and slide strain relief down cable.

2. Phillips Screw

3. Handle

Remove screw, and handle.

4. Power Pin Connector

Use 13 and 17 mm wrenches to remove power pin style connector.

4

5-6. Installing Dinse Style Connector To Adapt Spoolmate 100/150 Models For Use With

The Syncrowave 210

1

!

Turn Off welding power source and disconnect spool gun.

1. Dinse Style Connector

Screw on Dinse style connector and tighten with 13 and 17 mm wrenches.

Slide handle back into position, and secure with Phillips screw removed earlier.

Slide strain relief into position, and tighten strain relief cap.

OM-261726 Page 16

.


5-7. Adapter Cord Connections To Adapt Spoolmate 100/150 Models For Use With The

Syncrowave 210

1

!

Turn Off welding power source before connecting adapter cable.

1. 4 To 14-Pin Adapter

2. 14-Pin Receptacle

Insert spool gun control cable 4-pin plug into matching receptacle on

4-pin adapter cord and tighten collar.

Connect 14 − pin plug end of adapter cord to matching 14-pin receptacle on welding power source and tighten collar.

2

805521-A

5-8. Electrical Service Guide

Elec Serv 2017-01

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

Input Voltage (V)

Rated Maximum Supply Current

I

1max

(A)

Maximum Effective Supply Current

I

1eff

(A)

Max Recommended Standard Fuse Rating In Amperes

1

Time-Delay Fuses

2

Normal Operating Fuses

Min Input Conductor Size In AWG (mm

2

)

4

3

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG (mm

2)

4

230 Volts AC

24

11

30

35

14

48(15)

14

60 Hz Single-Phase

115 Volts AC

A 15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required.

See Section 5-10

Reference: 2017 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.

2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167 ° F (75 ° C) with not more than three single current − carrying conductors in a raceway. 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-261726 Page 17

.


5-9. Input Power Extension Cord Data

Use extension cord only for temporary wiring. Remove extension cord immediately after completing the project.

Cord Type Minimum Conductor Size Number of Conductors

Input 17 2018-11

Maximum Cord Length

Heavy Duty (Hard Usage) 12 AWG (4 mm

2

) 3 50 ft (15 m)

.

Read OSHA Standard 1910.334 for more information on the use of cord and plug connected equipment.

Read National Electrical Code (NEC) Article 590 for more information on temporary wiring.

5-10. Connecting 115 Volt Input Power

!

Installation must meet all National and Local Codes

− have only qualified persons make this installation.

!

Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC

Section 20.

.

The Auto-Line circuitry in this unit automatically links the power source to the primary voltage being applied, either

115 or 230 VAC.

For 115 volts AC input power, a 15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required.

1. Multi-Voltage Plug And Power Cord Connector (NEMA

Type 5 − 15P Plug Shown)

For multi −

voltage plug connections, see Section 5-12.

2. Receptacle − NEMA Type 5 − 15R (Customer Supplied)

1

2

Input6 2011 − 03 Ref. 805474-A Ref. 805519-A

OM-261726 Page 18

.


5-11. Connecting 1-Phase 230 Volt Input Power

1

3

7

2

4

L1

L2

5

= GND/PE Earth Ground

6

1

8

L2

9

230 VAC, 1

L1

Tools Needed:

input4 2012 − 05 − Ref. 803766-C / Ref. 805519-A / Ref. 805540-A

OM-261726 Page 19

.


5-11. Connecting 1-Phase Input Power (Continued)

!

Installation must meet all National and

Local Codes − have only qualified persons make this installation.

!

Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

!

Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

.

The Auto-Line circuitry in this unit automatically links the power source to the primary voltage being applied, either 115 or 230 VAC.

See rating label on unit and check input voltage available at site.

1. Input Power Cord

2. Disconnect Device (switch shown in the

OFF position)

3. Disconnect Device Grounding Terminal

4. Disconnect Device Line Terminals

5 Black And White Input Conductor (L1

And L2)

6. Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

7. Over-Current Protection

Select type and size of over-current protec-

tion using Section 5-8 (fused disconnect

switch shown).

Close and secure door on disconnect device.

Follow established lockout/tagout procedures to put unit in service.

8. Multi-Voltage Plug And Power Cord

Connector (NEMA 6-50P Plug Shown)

For multi − voltage plug connections, see Sec-

tion 5-12.

9. Receptacle (NEMA 6-50R)

(Customer Supplied)

Connect plug to receptacle.

input4 2012 − 05 − 803766-C

Notes

OM-261726 Page 20

.


5-12. Multi − Voltage Plug (MVP) Connection

2

Selecting Plug

1

3

4

5

!

Do not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty.

6

7

Connecting Plug To Power Cord

Selecting Plug

1. Power Cord Connector From

Welding Power Source

Select plug for power supply receptacle available at site. Not all plugs shown are provided as standard with unit.

2. Plug − NEMA Type 5 − 15P

3. Receptacle − NEMA Type 5 − 15R

(Customer Supplied)

4. Plug − NEMA Type 5 − 20P (Optional

Part No. 219259)


(Customer Supplied)

6. Plug − NEMA Type 6 − 50P


(Customer Supplied)

!

Follow electrical service guide for

230 VAC in Section 5-8. Do not use

plug rating to size branch circuit protection.

Connecting Plug To Power Cord

Align arrow on plug with arrow on power cord connector. Push together.

Tighten threaded collar. As threaded collar is tightened, push plug onto adapter until collar is completely tight.

Connect plug to receptacle.

MVP Plug1 2012 − 03 / Ref. 803812-C

OM-261726 Page 21

.


SECTION 6

−

OPERATION

6-1. Syncrowave 210 Controls

3

4

1

5

2

6

7

8

1. Amperage Adjustment Control

Use control to change preset amperage value. If a remote control is used, preset amperage value is the maximum amperage output available. This control also functions as a parameter change control while in the

menu mode (see Sections 6-2 thru 6-7).

2. Memory Card Port And Indicator

This port is used to add features to the machine and update software to the boards within the machine. Indicator is lit while card is being accessed.

3. Volt Meter

Displays actual voltage when voltage is present at the weld output terminals. It is also used to display parameter descriptions while in the menu.

4. Ammeter

Displays actual amperage while welding and preset amperage while idle. It is also used to display parameter selection options while in the menu.

5. Menu Button

Press button to scroll through available parameters for the selected process. Hold button to enter set-up mode (see Sections

6-2 thru 6-7).

268890-B/ 805521-A

6. Output ON Indicator

Blue indicator illuminates when output is on.

7. Process Selector

Use to select one of the following processes:

• AC TIG - Used for welding aluminum.

•

DC TIG - (DCEN) Used for welding mild and stainless steel.

• DC Stick - (DCEP) Used for welding steels.

• MIG - (Optional Expansion)

8. Power Switch

The memory card port uses an SD memory card.

.

8 GB max SD memory card.

SD Logo is a trademark of the 3C.

OM-261726 Page 22

.


6-2. Accessing Control Panel Menu: AC TIG

2

3

4

1

1. Menu Button

Press Menu button to cycle through parameters that can be set.

2. Parameter Display

3. Setting Display


Rotate Amperage Adjustment Control to adjust parameter setting.

150A

AC.AV

BAL

150A

75%

268890-B

Amperage Control:

Controls the average AC welding amperage output.

Limits the maximum output of a remote amperage device.

[BAL] Balance Control:*

(% EN)

Controls Oxide Cleaning

Increasing setting reduces oxide cleaning. Range is

60 to 80%. (See tips below)

FREQ

PPS

*

PRO − SET

provides PROfessionally developed SETtings for the weld process.

To use PRO − SET, press the menu button to display the parameter and adjust the

Amperage Adjustment Control until

PRO − SET flashes on the display. PRO −

SET flashes one time and reveals the professional setting for the parameter.

120H

OFF

TIP: AC Balance

controls the cleaning action. If floating black spots appear in the puddle, the balance setting is too high.

Turn the balance down until puddle becomes clear.

[FREQ] Frequency Control

:

*

Increasing setting narrows arc width range 60 to 150

Hertz. (See tips below)

[PULS] Pulse Control

:

Reduces heat input to minimize distortion and increase travel speed. Set PPS (pulses per second).

The range is OFF − 50 PPS. The background amperage and peak amperage are not adjustable. Background amperage equals 25% of peak amperage.

Peak amperage time equals 40%.

TIP: AC Frequency

controls the width of the arc cone. For thin fillet welds (less than 1/4 in.) set the frequency to 120 Hz.

This frequency setting provides a focused stable arc and produces a narrow weld.

For outside corner or groove welds on heavy material, a wide weld may be required. Lower the frequency to between

70 and100 Hz. This frequency setting produces a wider weld.

OM-261726 Page 23

.


6-3. Accessing DC TIG Control Panel Menu

2

3

150A

4

1

1. Menu Button



3. Setting Display

4. Amperage Adjustment

Control

Rotate Amperage Adjustment

Control to adjust parameter setting.


Controls the welding amperage output. Limits the maximum output of a remote amperage device.

[PULS] Pulse Control

:

Reduces heat input to minimize distortion and increase travel speed. Set PPS (pulses per second). The range is

OFF − 150 PPS. The background amperage and peak amperage are not adjustable.

Background amperage equals

25% of peak amperage. Peak amperage time equals 40%.

PPS OFF

6-4. Accessing DC Stick Control Panel Menu

268890-B

2

3

150A

4

1

1. Menu Button



3. Setting Display

4. Amperage Adjustment

Control

Rotate Amperage Adjustment

Control to adjust parameter setting.


Controls the welding amperage output. Limits the maximum output of a remote amperage device.

[DIG] Arc Force Control:

Controls the amount of additional amperage at low voltage (short arc length) conditions. Adjust the force of the arc for different joint configurations and electrodes. Range is

OFF − 100%.

DIG

OM-261726 Page 24

30%

268890-B

.


6-5. Accessing Spool Gun Control Panel Menu

2 3 4

1

1. Menu Button



3. Setting Display



14.0V

Voltage Control:

Controls the welding voltage output.

[WFS] Wire Feed Speed:

Controls the speed of the wire feed, with a minimum of 0.0and a maximum of 10.0.

WFS

Notes

0.0

268890-B

OM-261726 Page 25

.


6-6. Accessing User Setup Menu: AC And DC TIG

2

3

4

1. Menu Button

Press and hold Menu button for approximately two seconds to access machine configuration menus. Use Menu button to cycle through parameters that can be set.


3. Setting Display



1

USER

MENU

STRT

RMT

TUNG

POST

HF

STD

3/32

AUTO

Arc Starting Method Selection:

[STRT] [HF]

Is a non-contact starting method.

[STRT] [Lift]

Is a contact starting method.

Remote Starting Method Selection:

Remote Starting Options for Lift Arc.

[RMT] [STD]

Standard Remote Control.

[Out] [On]

Output On.

Tungsten Diameter Selection:

Each tungsten size has preset starting parameters specific to that diameter for optimized starting. Range is 0.040 in. to (1/8 in.) and 0.5 mm − 3.2 mm.

Post Flow Control Selection:

[POST] [AUTO]

Controls the length of time gas flows after welding stops. Range is AUTO, OFF − 50T

(seconds). AUTO calculates the time based on the maximum amperage of each welding cycle. The minimum time is 8 seconds. Auto = maximum amperage/10.

268890-B

OM-261726 Page 26

.


6-7. Accessing User DC Stick Setup Menu

2

3

4

1. Menu Button

Press and hold Menu button for approximately 2 seconds to access machine configuration menus. Use

Menu button to cycle through parameters that can be set.


3. Setting Display



USER MENU

1

OCV

NORM

Arc Starting Method Selection:

[OCV] [NORM]

Normal open circuit voltage for arc starting.

[OCV] [LOW]

Low open circuit voltage for arc starting.

268890-B

OM-261726 Page 27

.


6-8. Accessing User Spool Gun Setup Menu

2

3

4

1. Menu Button

Press and hold Menu button for approximately two seconds to access machine configuration menus. Use



3. Setting Display



USER

MENU

150A

150A

1

GUN

PROC

WIRE

MAT

S150

C25

0.030

18 GA

Spool Gun Selection:

[Gun] [S100]

[Gun] [S150]

Spool Gun Wire Diameter

Selection:

[Wire] [0.024]

[Wire] [0.030]

[Wire] [0.035]

Spool Gun Material Thickness

Selection:

[MAT] [24GA] / [22GA] / [20GA]

[MAT] [18GA] / [16GA] / [14GA]

[MAT] [1/8] / [3/16] / [1/4] [5/16]

[MAT] [3/8]

Spool Gun Process Selection:

[PROC] [FLUX]

[PROC] [TRI]

[PROC] [C25]

[PROC] [C100]

[PROC] [4043]

[PROC] [5356]

268890-B

OM-261726 Page 28

.


SECTION 7

−

ADVANCED MENU FUNCTIONS

7-1. Accessing Tech Menu

2

TECH

3

4

MENU

1

1. Menu Button

Press and hold Menu button for approximately 4 seconds to scroll past User Menu to Tech Menu. Use



3. Setting Display



To exit user menu, press and hold menu button approximately one second, or turn power off.

.

Settings in the Tech Menu are global, meaning they may pertain to all or some of the process.

ARC

MACH

CAL

CAL

SOFT

SERL

T/CY

RSET

LOW

0.0

HIGH

0.0

NUM

NUM

268890-B

[ARC] [T/CY] Arc Timer:

Monitors hours, minutes, and cycles of valid arc on. To view, rotate Amperage Adjustment Control. To reset, rotate Amperage Adjustment Control until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000].

[MACH] [Reset] Machine Reset::

Resets all machine values back to factory defaults. To reset, turn Amperage Adjustment Control to [RESET]

[YES]. Then press Menu button. [RESET] [DONE] will be displayed when the reset is complete and factory defaults have been restored.

[CAL] [LOW] Calibrate Low:

Calibrates low drive roll speed to provide consistent wire feed speed between various spools of wire and spool guns. To calibrate, press and hold the trigger, allowing the wire to feed until it stops. Then measure the wire, and subtract from 24 (24 − wire length =

Cal Low.

.

The Wire Feed Speed does not adjust in the Tech Menu, but does adjust in the Weld Process.

[CAL] [HIGH] Calibrate High:

Calibrates high drive roll speed to provide consistent wire feed speed between various spools of wire and spool guns. To calibrate, press and hold the trigger, allowing the wire to feed until it stops. Then measure the wire, and subtract from 24 (24 − wire length =

Cal High.

.

The Wire Feed Speed does not adjust in the Tech Menu, but does adjust in the Weld Process.

[SOFT] [NUM] Software Number:

Use Amperage Adjustment Control to select desired board to read software version and number.

[SERL] [NUM] / [NA] Serial Number:

This feature has not been implemented.

OM-261726 Page 29

.


SECTION 8

−

MAINTENANCE AND TROUBLESHOOTING

8-1. Routine Maintenance

!

Disconnect power before maintaining.

.

Maintain more often during severe conditions.

n

= Check

Z

= Change

~

= Clean

* To be done by Factory Authorized Service Agent

Δ

= Repair l

= Replace

Every

3

Months

Every

3

Months nl Labels n l Gas Hoses n Δ l Cables And Cords

Every

6

Months

~

:Durning heavy service, clean monthly.

8-2. Circuit Breaker CB1

1. Supplementary Protector CB1

If CB1 opens, unit will be completely inoperative.

If CB1 opens repeatedly, have a Factory Authorized Service Agent check unit..

1

805521-A

OM-261726 Page 30

.


8-3. Meter Troubleshooting Displays

1

RELE

TRIG GER

Repeat

.

All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.

1.

Typical meter display may be in several segments. Each segment is shown for two seconds, and then scrolls to the remaining segments of the display. The message then repeats itself.

Release Trigger Error:

w

[RELE] [ASE]/[TRIG] [GER]

Remote 14 receptacle contactor control

(Pins A − B) must be opened before proceeding.

Communication Errors:

w

[SCOM] [SD]

Serial Communication to the memory card board has been lost. To clear error, turn off power. If error does not clear or happens frequently

, contact a Factory Authorized

Service Agent.

w

[SCOM] [UI]

Serial Communication to the user interface card board has been lost. To clear error, turn off power. If error does not clear or happens frequently

, contact a Factory Authorized

Service Agent.

Over Temperature Errors:

w

[INV] [OT]

Over temperature condition in the primary inverter circuitry has occurred. Error will clear after the temperature has reached acceptable levels.

w

[PFC] [OT]

Over temperature condition in the primary power factor correction circuitry has occurred. Error will clear after the temperature has reached acceptable levels.

w

[SEC] [OT]

Over temperature of the weld output circuitry has occurred. Error will clear after the temperature has reached acceptable levels.

Temperature Sensor Failure:

w

[INV] [ERRT]

Indicates a short or open in the thermal protection circuitry located in the primary inverter circuitry of the unit. Contact a Factory

Authorized Service Agent if this display is shown.

w

[PFC] [ERRT]

Indicates a short or open in the thermal protection circuitry located in the primary power factor correction circuitry of the unit. Contact a Factory Authorized Service Agent if this display is shown.

w

[SEC] [ERRT]

Indicates a short or open in the thermal protection circuitry located in the weld output circuitry of the unit. Contact a Factory Authorized Service Agent if this display is shown.

Latching Errors:

w

[CLMP] [ERR]/[OVER] [VOLT]

Secondary clamp voltage too high.

Straighten out or shorten weld cables. If this does not correct the problem, contact a

Factory Authorized Service Agent.

w

[CLMP] [ERR]/[OVER] [AMPS]

Secondary clamp amperage too high.

Straighten out or shorten weld cables. If this does not correct the problem, contact a

Factory Authorized Service Agent.

Not Valid Error:

w

[Not] [Valid]

Indicates a non-allowable set-up on the front panel.

OM-261726 Page 31

8-4. Troubleshooting

.


.

The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.

There are no user serviceable parts inside unit.

Trouble

No weld output; unit completely inoperative.

Remedy

Place machine power switch in On position (see Section 6-1).

No weld output; unit on.

Unit provides only maximum or minimum weld output.

Erratic or improper weld output.

Place line disconnect switch in On position (see Section 5-11).

Check and replace line fuse(s), if necessary (see Section 5-11).

Check for proper input power connections (see Section 5-11).

Check, repair, or replace remote control.

Have Factory Authorized Service Agent check unit.

Make sure Material Amperage control is in proper position (see Section 6-1).

Have Factory Authorized Service Agent check unit.

Lay weld cables out straight, do not leave weld cables coiled.

Check position of Process Selector switch (see Section Figure 6-1).

Check position of Amperage control (see Section 6-1).

Make sure Material Amperage control is in proper position (see Section 6-1).

Select proper size tungsten (see Section 11-1).

No control of weld output.

Lack of high frequency; difficulty in starting GTAW arc.

Wandering arc direction of arc.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

− poor control of

Be sure torch cable is not close to any grounded metal.

Check cables and torch for cracked insulation or bad connections. Repair or replace.

Reduce gas flow rate (see Section 5-3).

Select proper size tungsten (see Section 11-1).

Properly prepare tungsten (see Section 11).

Shield weld zone from drafts.

Check and tighten all gas fittings.

Fan not operating.

No weld output; fan does not run.

No weld output; fan on.

Fan not operating; weld output available.

Properly prepare tungsten (see Section 11).

Unit equipped with Fan-On-Demand t . Fans run only when necessary. Unit equipped with circuitry to protect against overheating.

Place line disconnect switch in On position (see Section 5-11).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).

Check for proper input power connections (see Section 5-10 or 5-11).

Check connection to remote control receptacle (see Section 5-2).

Check remote control (see remote control Owner’s Manual).

Unit overheated. Allow unit to cool (see Section 4-7).

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

Error message [SCOM] [SD] is displayed.

Contact a Factory Authorized Service Agent.

Error message [SCOM] [UI] is displayed.


Error message [INV] [ERRT] is displayed.


OM-261726 Page 32

.


Trouble

Error message [PFC] [ERRT] is displayed.


Error message [SEC] [ERRT] is displayed.


Error message [CLMP] [ERR] [OVER]

[VOLT] is displayed.


Error message [CLMP] [ERR] [OVER]

[AMPS] is displayed.


Remedy

OM-261726 Page 33

.


SECTION 9

−

ELECTRICAL DIAGRAMS

OM-261726 Page 34

Figure 9-1. Circuit Diagram

262672-G

SECTION 10

−

HIGH FREQUENCY

10-1. Welding Processes Requiring High Frequency

1

1. High-Frequency Voltage

TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc.

TIG

10-2. Installation Showing Possible Sources Of HF Interference

high_freq 2018-01

13

Weld Zone

11, 12

50 ft

(15 m)

9

8

7

10

2

3

1

4 5 6

Best Practices

Not Followed

14

Sources of Direct High-Frequency

Radiation

1. High-Frequency Source (welding power source with built-in HF or separate HF unit)

2. Weld Cables

3. Torch

4. Work Clamp

5. Workpiece

6. Work Table

Sources of Conduction of High

Frequency

7. Input Power Cable

8. Line Disconnect Device

9. Input Supply Wiring

Sources of Reradiation of High

Frequency

10. Ungrounded Metal Objects

11. Lighting

12. Wiring

13. Water Pipes and Fixtures

14. External Phone and Power Lines

S-0694

OM-261726 Page 35

10-3. Recommended Installation To Reduce HF Interference

Weld Zone

3 50 ft

50 ft

(15 m)

5

6

1

4

2

8

7

8

Ground all metal objects and all wiring in welding zone using

#12 AWG wire.

Nonmetal

Building

Ground workpiece if required by codes.

Best Practices Followed

Metal Building

8

11

8

9

10

1. High-Frequency Source (welding power source with built-in HF or separate HF unit)

Ground metal machine case (clean paint from around hole in case, and use case screw), work output terminal, line disconnect device, input supply, and worktable.

2. Center Point of Welding Zone

Midpoint between high-frequency source and welding torch.

3. Welding Zone

A circle 50 ft (15 m) from center point in all directions.

4. Weld Output Cables

Keep cables short and close together.

5. Conduit Joint Bonding and Grounding

Electrically join (bond) all conduit sections using copper straps or braided wire.

Ground conduit every 50 ft (15 m).

6. Water Pipes and Fixtures

Ground water pipes every 50 ft (15 m).

7. External Power or Telephone Lines

Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.

8. Grounding Rod

Consult the National Electrical Code for specifications.

Ref. S-0695

Metal Building Requirements

9. Metal Building Panel Bonding

Methods

Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame.

10. Windows and Doorways

Cover all windows and doorways with grounded copper screen of not more than

1/4 in (6.4 mm) mesh.

11. Overhead Door Track

Ground the track.

OM-261726 Page 36

SECTION 11

−

SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2018-01

Whenever possible and practical, use DC weld output instead of AC weld output.

11-1. Selecting Tungsten Electrode (

Wear Clean Gloves To Prevent Contamination Of Tungsten

)

A. Select Tungsten Electrode.

.

Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference the product packaging to identify the tungsten you are using.

Electrode Diameter

Amperage Range - Gas Type

♦

- Polarity

(DCEN) − Argon AC − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

Unbalanced Wave

(For Use With Aluminum)

.010 in. (.25 mm)

.020 in. (.50 mm)

.040 in. (1 mm)

1/16 in. (1.6 mm)

3/32 in. (2.4 mm)

1/8 in. (3.2 mm)

5/32 in. (4.0 mm)

2% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

Up to 15

5-20

15-80

70-150

150-250

250-400

400-500

3/16 in (4.8 mm)

1/4 in. (6.4 mm)

500-750

750-1000

♦

Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).

Up to 15

5-20

15-80

70-150

140-235

225-325

300-400

400-500

500-630

B. Electrode Composition.

Tungsten Type

2% Cerium

(Grey*)

1.5

− 2% Lanthanum

(Yellow/Blue)

Application Notes

Good all − around tungsten for both AC and DC welding.

Excellent low amp starts for AC and DC welding.

2% Thorium

(Red)

Pure Tungsten

(Green)

Commonly used for DC welding, not ideal for AC.

Not Recommended for inverters!

For best results in most applications use a sharpened cerium or lanthanum electrode for AC and DC welding.

* Color may vary depending on manufacturer, please refer to manufacturer’s guide for color designation.

OM-261726 Page 37

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.

Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

2

1-1/2 To 4 Times

Electrode Diameter

4

1

Ideal Tungsten Preparation − Stable Arc

3

15 ° to 30 °

1. Grinding Wheel

Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.

2. Tungsten Electrode

A 2% ceriated tungsten is recommended.

3. Ideal Grind Angle Range: 15 ° to 30 °

.

30 degrees is the recommended electrode grind angle.

4. Straight Ground

Grind lengthwise,

not radial

.

Notes

OM-261726 Page 38

SECTION 12

−

GUIDELINES FOR TIG WELDING (GTAW)

Ref. gtaw_Phase_2018 − 01

12-1. Positioning The Torch

10 − 25

°

4

1

2

10 − 15

°

90

°

5

6

3/16 in

Bottom View Of Gas Cup

3

5

6

1/16 in

4

!

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 cerium or lanthanum based tungsten instead of thoriated. Thorium dust 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.

1. Workpiece

Make sure workpiece is clean before welding.

2. Work Clamp

Place as close to the weld as possible.

3. Torch

4. Filler Rod (If Applicable)

5. Gas Cup

6. Tungsten Electrode

Select and prepare tungsten

according to Section 11-2.

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.

The tungsten extension should be no greater than the inside diameter of the gas cup.

Arc length is the distance from the tungsten to the workpiece.

Ref.161892

OM-261726 Page 39

12-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool

Tungsten With Filler Rod

Welding direction

Form pool

Tilt torch

Tilt torch

75

°

75

°

15

°

Move torch to front of pool. Repeat process.

Add filler metal

Remove rod Move torch to front of pool. Repeat process.

12-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead

“T” Joint

20

°

90

°

70

°

75

°

162002-B

20-40

°

20

°

Lap Joint

10

°

15

°

Corner Joint

90

°

75

°

75

°

15

°

30

°

OM-261726 Page 40

15

°

162003 / 0792

SECTION 13

−

STICK WELDING (SMAW) GUIDELINES

13-1. Stick Welding Procedure

Tools Needed:

1

2

7

4

5

Equipment Needed:

Constant Current

Welding Power Source

6

3

!

Weld current starts when electrode touches workpiece.

!

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.

.

Always wear appropriate personal protective clothing.

1. Workpiece

Make sure workpiece is clean before welding.

2. Work Clamp

Place as close to the weld as possible.

3. Electrode

Before striking an arc, insert an electrode in the electrode holder. A small diameter electrode requires less current than a large one. Follow recommendations of the electrode manufacturer when setting weld amperage (see Section

13-2).

4. Insulated Electrode Holder

5. Electrode Holder Position

6. Arc Length

Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. Correct arc length is related to electrode diameter. Examine the weld bead to determine if the arc length is correct.

Arc length for 1/16 and 3/32 in. diameter electrodes should be about

1/16 in. (1.6 mm); arc length for 1/8 and 5/32 in. electrodes should be about 1/8 in. (3 mm).

7. Slag

Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.

stick 2018-01 − 151593

OM-261726 Page 41

13-2. Electrode And Amperage Selection Chart

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

7/32

1/4

3/32

1/8

5/32

3/16

7/32

1/4

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

3/32

1/8

5/32

3/16

3/32

1/8

5/32

3/32

1/8

5/32

3/16

7/32

1/4

3/32

1/8

3/32

1/8

5/32

3/16

7/32

1/4

1/16

5/64

13-3. Striking An Arc

6010

6011

6013

EP

EP

EP,EN

ALL

ALL

ALL

DEEP

DEEP

LOW

MIN. PREP, ROUGH

HIGH SPATTER

7014

7018

EP,EN

EP

ALL

ALL

MED

MED

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

7024 EP,EN

FLAT

HORIZ*

LOW

NI-CL

308L

EP

EP

ALL

ALL

LOW

LOW

CAST IRON

STAINLESS

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

1

1

3

3

2

2

Ref. S-087 985-A

!

Weld current starts when electrode touches workpiece.

1. Electrode

2. Workpiece

3. Arc

Scratch Technique

Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

Tapping Technique

Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

S-0049 / S-0050

OM-261726 Page 42

13-4. Positioning Electrode Holder

1

90

°

90

°

10

°

-30

°

2

1. End View Of Work Angle

2. Side View Of Electrode

Angle

After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode.

Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the direction of travel) will be helpful.

.

To produce the best results, hold a short arc, travel at a uniform speed, and feed the electrode downward at a constant rate as it melts.

Groove Welds

1

45

°

45

°

Fillet Welds

13-5. Poor Weld Bead Characteristics

10

°

-30

°

2

S-0060

1. Large Spatter Deposits

2. Rough, Uneven Bead

3. Slight Crater During Welding

4. Bad Overlap

5. Poor Penetration

2

3

4

1

13-6. Good Weld Bead Characteristics

1

2 3 4

5

S-0053-A

5

1. Fine Spatter

2. Uniform Bead

3. Moderate Crater During

Welding

Weld a new bead or layer for each

1/8 in. (3.2 mm) thickness in metals being welded.

4. No Overlap

5. Good Penetration into Base

Metal

S-0052-B

OM-261726 Page 43

13-7. Conditions That Affect Weld Bead Shape

Electrode Angle

Angle Too Small

Correct Angle

10

°

-

30

°

Drag

Angle Too Large

Arc Length

Travel Speed

Too Short

Slow

Normal

Normal

13-8. Electrode Movement During Welding

Too Long

Spatter

Fast

.

Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.

S-0061

1

3

2

.

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.

1. Stringer Bead − Steady

Movement Along Seam

2. Weave Bead − Side to Side

Movement Along Seam

3. Weave Patterns

Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode.

S-0054-A

13-9. Welding Lap Joints

30

°

Or Less

1

30

°

Or Less

1

1. Electrode

2. Single-Layer Fillet Weld

Move electrode in circular motion.

3. Multi-Layer Fillet Weld

Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.

Weld both sides of joint for maximum strength.

2

OM-261726 Page 44

3

S-0063 / S-0064

13-10. Welding Groove (Butt) Joints

1

3

13-11. Welding T-Joints

1

2

45

Or

°

Less

2

30

°

2

4

1. Tack Welds

Prevent butt joint distortion by tack welding the materials in position before final weld.

Workpiece distortion occurs when heat is applied locally to a joint.

One side of a metal plate will curl up toward the weld. Distortion will also cause the edges of a butt joint to pull together ahead of the electrode as the weld cools.

2. Square Groove Weld

3. Single V-Groove Weld

4. Double V-Groove Weld

Materials up to 3/16 in. (5 mm) thick can often be welded without special preparation using the square groove weld. However, when welding thicker materials it may be necessary to prepare the edges (V-groove) of butt joints to ensure good welds.

The single or double V-groove weld is good for materials 3/16 −

3/4 in. (5-19 mm) thick. Generally, the single V-groove is used on materials up to 3/4 in. (19 mm) thick and when, regardless of thickness, you can weld from one side only.

Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.

S-0062

3

1

1. Electrode

2. Fillet Weld

Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface.

For maximum strength weld both sides of upright section.

3. Multi-Layer Deposits

Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section

13-8. Remove slag before making

another weld pass.

S-0060 / S-0058-A / S-0061

OM-261726 Page 45

13-12. Weld Test

3

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

2

1

2

13-13. Troubleshooting

3

1

1. Vise

2. Weld Joint

3. Hammer

Strike the weld joint in the direction shown. A good weld bends over but does not break.

If the weld breaks, examine it to determine the cause.

If the weld is porous (many holes), the arc length was probably too long.

If the weld contains bits of slag, the arc may have been too long or the electrode was moved incorrectly which allowed molten slag to be trapped in the weld. This may happen on a V-groove joint made in several layers and calls for additional cleaning between layers.

If the original beveled surface is visible the material was not fully melted which is often caused by insufficient heat or too fast a travel speed.

S-0057-B

Porosity

− small cavities or holes resulting from gas pockets in weld metal.

Possible Causes

Arc length too long.

Damp electrode.

Workpiece dirty.

Corrective Actions

Reduce arc length.

Use dry electrode.

Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.

Excessive Spatter

− scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes

Amperage too high for electrode.

Arc length too long or voltage too high.


Decrease amperage or select larger electrode.

Reduce arc length or voltage.

Incomplete Fusion

− failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes

Insufficient heat input.

Improper welding technique.

Workpiece dirty.

OM-261726 Page 46


Increase amperage. Select larger electrode and increase amperage.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.

Lack Of Penetration

− shallow fusion between weld metal and base metal.

Lack of Penetration

Good Penetration

Possible Causes

Improper joint preparation.

Improper weld technique.

Insufficient heat input.


Material too thick. Joint preparation and design must provide access to bottom of groove.

Keep arc on leading edge of weld puddle.

Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

Excessive Penetration

− weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Good Penetration

Possible Causes

Excessive heat input.


Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Burn-Through

− weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes



Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Waviness Of Bead

− weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes

Unsteady hand.


Use two hands. Practice technique.

Distortion

− contraction of weld metal during welding that forces base metal to move.

Possible Causes


Base metal moves in the direction of the weld bead.


Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-261726 Page 47

Notes

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

16 Gauge (.063 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

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Effective January 1, 2020

(Equipment with a serial number preface of NA or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.

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1.

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