Miller SYNCROWAVE 300 CE Owner’s Manual

OM-289396D

2022-05

2021-01

Description

380-400V Arc Welding Power Source

208-240/480V Arc Welding Power Source

Syncrowave

®

Syncrowave 300

For product information,

Owner’s Manual translations, and more, visit

www.MillerWelds.com

For product information,

Owner’s Manual translations, and more, visit

www.MillerWelds.com

OWNER’S MANUAL

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 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.

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

Miller is the first welding equipment manufacturer in the

U. S. A. to be registered to the

ISO 9001 Quality System

Standard.

Mil_Thank1 2019 01

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1

1-2

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

Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3

1-4

1-5

1-6

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

California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-2

2-3

Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 7

2-4

2-5

Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-6 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-1

3-2

Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-1

4-2

Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-3

4-4

4-5

4-6

Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-7

4-8

Dimensions, Weights, And Mounting Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-9 Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-10 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-1 Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-2

5-3

5-4

5-5

Selecting Cable Sizes 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connecting Weld Cables, Remote Control, And Shielding Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Cooler Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-6

5-7

Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-8 Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 6 – SYNCROWAVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6-1

6-2

6-3

6-4

Syncrowave Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Accessing Process Menu: AC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Accessing Process Menu: DC TIG And DC TIG Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Accessing Process Menu: DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6-5

6-6

Accessing User Menu: AC/DC TIG And DC TIG Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Accessing User Menu: DC Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION 7 – ADVANCED MENU FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7-1 Accessing Tech Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7-2

7-3

Summary Of Default And Pro-Set Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION 8 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8-1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8-2

8-3

Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8-4

8-5

Voltmeter/Ammeter Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9-1 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SECTION 10 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 11 – HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

11-1 Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

11-2 Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

11-3 Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION 12 – SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES. . . . . . . . . . . . . . . . 44

TABLE OF CONTENTS

12-1 Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

12-2 Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines. . . . . . . . . . . . . . 45

SECTION 13 – TIG PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

13-1 Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 14 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

14-1 Electrode And Amperage Selection Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

DECLARATION OF CONFORMITY  for European Community (CE marked) products.

MILLER Electric Mfg. LLC, 1635 Spencer Street, Appleton, WI 54914 U.S.A.

declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s), Commission Regulation(s) and Standard(s).

Product/Apparatus Identification:

Product

Syncrowave 300 380-400

Stock Number

907782002

Council Directives and Commission Regulations:

•

2014/35/EU Low voltage

•

2014/30/EU Electromagnetic compatibility

•

2009/125/EC and regulation 2019/1784 Ecodesign requirements for energy-related products

•

2011/65/EU and amendment 2015/863 Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

•

EN IEC 60974-1:2018/A1:2019 Arc welding equipment – Part 1: Welding power sources

•

EN IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices

•

EN 60974-10:2014/A1:2015 Arc welding equipment – Part 10: Electromagnetic compatibility requirements

•

EN IEC 63000:2018 – Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances

Signatory:

April 21, 2022

_____________________________________

___________________________________________

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

Date of Declaration

289398C

DECLARATION OF CONFORMITY  for European Community (CE marked) products.

MILLER Electric Mfg. LLC, 1635 West Spencer Street, Appleton, WI 54914 U.S.A.

declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s), Commission Regulation(s) and Standard(s).


Product

Syncrowave 300 Tigrunner 380-400

Stock Number

907782003

Council Directives and Commission Regulations:

•

2014/35/EU Low voltage

•

2014/30/EU Electromagnetic compatibility

•

2009/125/EC and regulation 2019/1784 Ecodesign requirements for energy-related products

•

2011/65/EU and amendment 2015/863 Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

•

EN IEC 60974-1:2018/AI:2019 Arc welding equipment – Part 1: Welding power sources

•

EN IEC 60974-2:2019 Arc welding equipment – Part 2: Liquid cooling systems

•

IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices

•


•

EN IEC 63000:2018 – Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances

Signatory:

April 21, 2022

_____________________________________

___________________________________________

David A. Werba


289417C

Date of Declaration

DECLARATION OF CONFORMITY

For United Kingdom (UKCA marked) products.


declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Regulation(s) and Standard(s).


Product

Syncrowave 300 380-400

Stock Number

907782002

Regulations:

•

S.I. 2016/1101 Electrical Equipment (Safety) Regulations 2016

•

S.I. 2016/1091 Electromagnetic Compatibility Regulations 2016

•

S.I. 2021/745 Ecodesign for Energy-Related Products and Energy Regulations 2021

•

S.I. 2012/3032 Restriction of the Use of Certain Hazardous Substances in Electrical and

Electronic Equipment Regulations 2012

Standards:

•

EN IEC 60974-1:2018/A1:2019 Arc welding equipment

– Part 1 Welding power sources

•

EN IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices

•


•

EN IEC 63000:2018 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances

Signatory:

April 21, 2022

_____________________________________

___________________________________________

David A. Werba


Date of Declaration

290425B

DECLARATION OF CONFORMITY

For United Kingdom (UKCA marked) products.


declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Regulation(s) and Standard(s).


Product

Syncrowave 300 Tigrunner 380-400

Stock Number

907782003

Regulations:

•

S.I. 2016/1101 Electrical Equipment (Safety) Regulations 2016

•

S.I. 2016/1091 Electromagnetic Compatibility Regulations 2016

•

S.I. 2021/745 Ecodesign for Energy-Related Products and Energy Regulations 2021

•

S.I. 2012/3032 Restriction of the Use of Certain Hazardous Substances in Electrical and

Electronic Equipment Regulations 2012

Standards:

•

EN IEC 60974-1:2018/A1:2019 Arc welding equipment – Part 1 Welding power sources

•

EN IEC 60974-2:2019 Arc welding equipment

– Part 2: Liquid cooling systems

•

IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices

•


•

EN IEC 63000:2018 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances

Signatory:

April 21, 2022

_____________________________________

___________________________________________

David A. Werba


Date of Declaration

290428B

EMF DATA SHEET FOR ARC WELDING POWER SOURCE

Product/Apparatus Identification

P r o d u c t

SYNCROWAVE 300 380-400, CE

SYNCROWAVE 300 TIGRUNNER 380-400, CE

907782002

907782003

S t o c k N u m b e r

Compliance Information Summary

Applicable regulation Directive 2014/35/EU

Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC

Applicable standards

Intended use

IEC 62822

−

1:2016, IEC 62822 for occupational use

−

2:2016 for use by laymen

Non

−

thermal effects need to be considered for workplace assessment

Thermal effects need to be considered for workplace assessment

YES

YES

NO

NO

Data is based on maximum power source capability (valid unless firmware/hardware is changed)

Data is based on worst case setting/program (only valid until setting options/welding programs are changed)

Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)

Occupational exposure is below the Exposure Limit Values (ELVs) for health effects at the standardized configurations

Occupational exposure is below the Exposure Limit Values (ELVs) for sensory effects at the standardized configurations n.a

YES NO

(if applicable and NO, specific measures are needed)

Occupational exposure is below the Action Levels (ALs) at the standardized configurations n.a

YES NO

(if applicable and NO, specific signage is needed)

EMF Data for Non-thermal Effects

Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)

S t a n d a r d i z e d d i s t a n c e

ELV EI @ standardized distance

Required minimum distance

Sensory

Effects

1 0 c m

0.1

1 cm

Head

Health

Effects

1 0 c m

0.04

1 cm

YES NO

(if NO, specific required minimum distances apply)

Trunk

1 0 c m

0.06

1 cm

Limb (hand)

3 c m

0.03

1 cm

Limb (thigh)

3 c m

0.07

1 cm

Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)

Distance where all general public ELV Exposure Indices fall below 1.00 (100%)

Tested by:

289400-A

Joe Krueger Date tested: 2021

−

01

−

05

1 cm

1 cm

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

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

1-1.

Symbol Usage

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.

�

Indicates special instructions.

1-2.

Arc Welding 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. 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.

� Do not touch live electrical parts.

� Wear dry, hole-free insulating gloves and body protection.

� Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

� Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling.

� Use AC output ONLY if required for the welding process.

� If AC output is required, use remote output control if present on unit.

� 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

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.

(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!

� 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).

� Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.

� 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.

� When making input connections, attach proper grounding conductor first—double-check connections.

� Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

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

� Turn off all equipment when not in use.

� Do not use worn, damaged, undersized, or repaired cables.

� Do not drape cables over your body.

� If earth grounding of the workpiece is required, ground it directly with a separate cable.

� Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

� Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

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

� Wear a safety harness if working above floor level.

� Keep all panels and covers securely in place.

� Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

� Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

� Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.

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

OM-289396 Page 1

HOT PARTS can burn.

� Do not touch hot parts bare handed.

� Allow cooling period before working on equipment.

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

FLYING METAL OR DIRT can injure eyes.

� Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

� Wear approved safety glasses with side shields even under your welding helmet.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

� Keep your head out of the fumes. Do not breathe the fumes.

� 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.

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

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

� 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.

� 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.

� 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.

BUILDUP OF GAS can injure or kill.

� Shut off compressed gas supply when not in use.

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

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.

� 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).

� Wear approved safety glasses with side shields under your helmet.

� Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc.

� Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

OM-289396 Page 2

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.

� Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

� Do not weld where flying sparks can strike flammable material.

� Protect yourself and others from flying sparks and hot metal.

� Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

� Watch for fire, and keep a fire extinguisher nearby.

� Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

� 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.

� 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 (see Safety Standards).

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

� 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.

� Do not use welder to thaw frozen pipes.

� Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

� Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

� Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

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

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

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

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

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

� Wear approved ear protection if noise level is high.

ELECTRIC AND MAGNETIC FIELDS

(EMF) can affect Implanted Medical

Devices.

� Wearers of Pacemakers and other Implanted Medical Devices should keep away.

� 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.

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.

� Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.

� Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

� Keep cylinders away from any welding or other electrical circuits.

� Never drape a welding torch over a gas cylinder.

� Never allow a welding electrode to touch any cylinder.

� Never weld on a pressurized cylinder—explosion will result.

� Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

� Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve.

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

� Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders.

� 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.

� Do not install or place unit on, over, or near combustible surfaces.

� Do not install unit near flammables.

� Do not overload building wiring — be sure power supply system is properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

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

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

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

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

� 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.

� Allow cooling period; follow rated duty cycle.

� Reduce current or reduce duty cycle before starting to weld again.

� Do not block or filter airflow to unit.

FLYING SPARKS can injure.

� Wear a face shield to protect eyes and face.

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

� Sparks can cause fires—keep flammables away.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handling boards or parts.

� Use proper static-proof bags and boxes to store, move, or ship PC boards.

MOVING PARTS can injure.

� Keep away from moving parts.

� Keep away from pinch points such as drive rolls.

WELDING WIRE can injure.

� Do not press gun trigger until instructed to do so.

� Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

� 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.

� Keep away from moving parts such as fans.

� Keep all doors, panels, covers, and guards closed and securely in place.

� Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.

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

READ INSTRUCTIONS.

� 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.

� Use only genuine replacement parts from the manufacturer.

� Perform installation, maintenance, and service according to the

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

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

� Have only qualified persons familiar with electronic equipment perform this installation.

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

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

� Have the installation regularly checked and maintained.

� Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

OM-289396 Page 3

ARC WELDING can cause interference.

� Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots.

� Be sure all equipment in the welding area is electromagnetically compatible.

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.

1-5.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://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.

Website: http://www.aws.org

.

National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org

.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com

.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org

.

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.

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

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

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

� If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

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

.

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 .

SOM 2022–01

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-289396 Page 4

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

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

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.

�

Indique des instructions spécifiques.

2-2.

Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de ce symbole, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les Normes de sécurité principales. Lire et suivre 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.

Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.

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.

� Ne pas toucher aux pièces électriques sous tension.

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

� S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.

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

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

MENT si le procédé de soudage le demande.

� Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

� D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures

Ce groupe de symboles veut dire Avertissement! Attention! DAN-

GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE-

CES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout danger.

métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque

élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante

(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste

à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !

� Couper l’alimentation ou arrêter le moteur avant de procéder

à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147

(voir normes de sécurité).

� Brancher correctement la mise à la terre et utiliser cet appareil conformément à son manuel d’utilisateur et aux codes nationaux, provinciaux et municipaux.

� Toujours vérifier la mise à la terre — vérifier et assurez-vous que le conducteur de mise à la terre du cordon d’alimentation est bien raccordé à la borne de mise à la terre dans le boîtier de déconnexion ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

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

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

� 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.

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

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

� Ne pas enrouler les câbles autour du corps.

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

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

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

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

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

OM-289396 Page 5

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

� 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.

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

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

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

LES PIÈCES CHAUDES peuvent provoquer des brûlures.

� Ne pas toucher des parties chaudes à mains nues.

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

� Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

DES PIECES DE METAL ou DES

SALETES peuvent provoquer des blessures dans les yeux.

� 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.

� Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

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

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

� 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.

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

� 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.

� Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours

à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

� Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

� Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

OM-289396 Page 6

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

� Fermer l’alimentation du gaz comprimé en cas de non utilisation.

� Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

� Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir

ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

� Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.

� 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.

� Porter une protection corporelle en cuir ou des vêtements ignifuges (FRC). La protection du corps comporte des vêtements sans huile, comme 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.

� 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.

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

� Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.

� Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

� Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

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

� 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.

� Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les Normes de Sécurité).

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

� 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.

� Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

� En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

� Porter une protection corporelle en cuir ou des vêtements ignifuges (FRC). La protection du corps comporte des vêtements sans huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

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

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

� Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

� 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.

� 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.

Le BRUIT peut endommager l’ouïe.

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

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

Les CHAMPS

ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

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

� 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.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

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

� 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.

� 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.

� Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.

� Ne jamais placer une torche de soudage sur une bouteille à gaz.

� Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.

� Ne jamais souder une bouteille pressurisée - risque d’explosion.

� 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.

� 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 lerégulateur lors de l’ouverture de la vanne.

� Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.

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

� 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.

Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

� Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables.

� Ne pas installer l’appareil à proximité de produits inflammables

� Ne pas surcharger l’installation électrique – s’assurer que l’alimentation est correctement dimensionné et protégé avant de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.

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

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

� 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.

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

� 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.

� Laisser l’équipement refroidir ; respecter le facteur de marche nominal.

� Réduire le courant ou le cycle opératoire avant de recommancer le soudage.

� Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

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

OM-289396 Page 7

� 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.

� Les étincelles risquent de causer un incendie - éloigner toute substance inflammable.

LES CHARGES

ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

� Établir la connexion avec la barrette de terre

AVANT de manipuler des cartes ou des pièces.

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

Les PIÈCES MOBILES peuvent causer des blessures.

� Ne pas s’approcher des organes mobiles.

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

LES FILS DE SOUDAGE peuvent provoquer des blessures.

� Ne pas appuyer sur la gachette avant d’en avoir reçu l’instruction.

� 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.

� 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.

� S’abstenir de toucher des organes mobiles tels que des ventilateurs.

� Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.

� 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.

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

LIRE LES INSTRUCTIONS.

� 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.

� N’utiliser que des pièces de remplacement provenant du fabricant.

� 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.

� 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.

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

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

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

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

� Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.

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

� L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

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

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

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

électronique sensible.

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

� En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

OM-289396 Page 8

2-4.

Proposition californienne 65 Avertissements

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

.

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.

2-5.

Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://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.

Website: http://www.aws.org

.

National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org

.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com

.

Safety in Welding, Cutting, and Allied Processes, 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 .

SOM_fre 2022–01

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: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques 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 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-289396 Page 9

1-1.

Additional Safety Symbols And Definitions

Some symbols are found only on CE products.

1-1.


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


Safe1 2012 05

1-1.


Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.

Contact your local recycling office or your local distributor for further information.

�

Complete Parts List is available at www.MillerWelds.com

Safe1 2012 05

Safe37 2017 04

3-1.

SECTION 3 – DEFINITIONS

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

facility.

facility.

Additional Safety Symbol Definitions

Safe1 2012 05

Safe1 2012 05

Safe37 2017 04

�


Do not discard product (where applicable) with general waste.


facility.

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

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.


Protect yourself from electric shock by insulating yourself from work and ground.

Safe2 2017 04

Safe37 2017 04

Safe37 2017 04

Safe2 2017 04

Safe2 2017 04

Safe3 2017 04

Wear dry insulating gloves. Do not touch electrode with bare hand.




Safe2 2017 04

Safe2 2017 04

Safe3 2017 04

Safe3 2017 04

Safe4 2017 04



Safe3 2017 04

Safe3 2017 04

Safe4 2017 04

Safe4 2017 04

Safe5 2017 04



Safe4 2017 04

Safe4 2017 04

Safe5 2017 04

Safe6 2017 04

Disconnect input plug or power before working on machine.


Keep your head out of the fumes.

Use ventilating fan to remove fumes.

Safe5 2017 04

Safe5 2017 04

Safe6 2017 04

Safe6 2017 04

Safe7 2017 04

Safe10 2012 05



Keep your head out of the fumes



Safe6 2017 04

Safe6 2017 04

Safe7 2017 04

Safe7 2017 04

Safe11 2012 05



Use forced ventilation or local exhaust to remove the fumes.

Keep flammables away from welding. Do not weld near flammables.

Safe7 2017 04

Safe7 2017 04

Safe8 2012 05

Safe12 2012 05

OM-




Safe8 2012 05

Safe8 2012 05

Safe9 2012 05

OM-

OM-



Welding sparks can cause fires. Have a fire extinguisher nearby, and

Safe9 2012 05

Safe9 2012 05

OM-

OM-

OM-289396 Page 10

Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe15 2012 05

Do not weld on drums or any closed containers.

Safe16 2017 04



Do not cut on drums or any closed containers.

Safe17 2017 04

Do not grip material near cutting path.

Safe16 2017 04

Safe17 2017 04

Safe18 2017 10


Turn off power before disassembling torch.

Safe17 2017 04

Safe19 2012 05

Do not remove or paint over (cover) the label.




Safe20 2017 04

OM-

Safe19 2012 05

Safe20 2017 04

OM-

Safe20 2017 04

OM-



Keep flammables away from welding. Do not weld near flammables.

Safe10 2012 05

Safe11 2012 05

Safe12 2012 05

Do not work on unit if engine is running. Stop engine first.

Do not work on unit if engine is running. Stop engine first.

Safe21 2017 04

Safe21 2017 04

Safe22 2017 04

Safe22 2017 04

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.


Stop engine before fueling.

Stop engine before fueling.

Safe14 2012 05

Safe17 2017 04

Safe23 2017 04

Safe23 2017 04


Do not grip material near cutting path.

�


Safe15 2012 05

Safe18 2017 10

Do not fuel a hot engine.

Do not fuel a hot engine.


Safe24 2017 04

Safe24 2017 04

Safe16 2017 04

Safe19 2012 05

Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye



Safe17 2017 04

Safe20 2017 04

Safe25 2012 05

OM-

When power is applied failed parts can explode or cause other parts to explode.

When power is applied failed parts can explode or cause other parts to explode.

Writer: If necessary, replace the word “handle” with “lift eye’.

Do not use one handle to lift or support unit.

Safe18 2017 10

Safe26 2012 05

Safe26 2012 05

Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.

when servicing unit.

Safe19 2012 05

Safe27 2012 05

Safe27 2012 05

Drive rolls can injure fingers.

Always wear long sleeves and button your collar when servicing unit.

Always wear long sleeves and button your collar when servicing unit.

Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away.

After taking proper precautions as shown, connect power to unit.



Safe33 2017 04


Safe28 2012 05

OM-

Safe29 2012 05

Safe29 2012 05

Consult rating label for input power requirements.

1-1.





Safe34 2012 05

Safe30 2012 05

Safe30 2012 05

OM-

OM-

Writer: If necessary, replace the word “handle” with “lift eye’.

Become trained and read the instructions and labels before working on machine.

Safe35 2012 05

Connect Green Or Green/Yellow grounding conductor to ground terminal first.

facility.


Connect input conductors (L1, L2, L3) to line terminals.

Contact your local recycling office or your local distributor for further


Safe36 2012 05

Wear hat and safety glasses. Use ear protection and button shirt col-

Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away.

collar. Use welding helmet with correct shade of filter. Wear complete


heavy shirt, cuffless trousers, high shoes, and a cap.

Safe33 2017 04

Safe38 2012 05

Safe2 2017 04

Wear hat and safety glasses. Use ear protection and button shirt

Consult rating label for input power requirements.

body protection.


Safe39 2012 05

OM-289396 Page 11

Become trained and read the instructions before working on the machine or welding.

Safe34 2012 05

Safe3 2017 04

Safe40 2012 05

Become trained and read the instructions before working on the machine or cutting.

Safe4 2017 04

Safe35 2012 05

Safe41 2012 05

Connect input conductors (L1, L2, L3) to line terminals.

Safe5 2017 04

Safe36 2012 05


Keep your head out of the fumes collar. Use welding helmet with correct shade of filter. Wear complete body protection.

Safe6 2017 04

Safe38 2012 05

Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.


Become trained and read the instructions before working on the machine or cutting.


OM-

OM-

?

Hazardous voltage remains on input capacitors after power is turned

Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 60 seconds pacitor voltage, and be sure it is near 0 before touching any parts.

pacitor voltage, and be sure it is near 0 before touching any parts.

Safe42 2017 04

Safe42 2017 04


Hazardous voltage remains on input capacitors after power is turned power is turned off before working on unit, AND check input capacitor

5 minutes after voltage, and be sure it is near 0 before touching any parts.

voltage, and be sure it is near 0 before touching any parts.

Safe43 2017 04

Safe43 2017 04

=< 60

°

=< 60

° Always lift and support unit using both handles. Keep angle of lifting


device less than 60 degrees.

Use a proper cart to move unit.


Safe64 2017 04

Safe44 2012 05

Safe44 2012 05



Engine fuel plus flames or sparks can cause fire.

Safe65 2012 06 �


Safe45 2012 05


=< 60

°

3

=< 60

°


Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

Remove unit from shipping crate. Remove Owner’s Manual from unit.

Follow instructions to install muffler.

Safe66 2012 06

Safe46 2012 05

Safe46 2012 05

Safe96 2012 06


Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 5 minutes after

Include extra length in grounding conductor and connect grounding conductor first. Connect black, white, and red wires (L1, L2, L3) to line terminals.

Read Owner’s Manual for battery maintenance information.

Safe47 2012 05

Safe97 2012 05

/

Safe40 2012 05

Always lift and support unit using both handles. Keep angle of lifting job site. Include extra length in grounding conductor and connect grounding conductor first. Connect line input conductors as shown on

Become trained and read the instructions before working on the

+ + inside label. Double-check all connections, jumper link positions, and input voltage before applying power.

Safe117 2014 06 input voltage before applying power.

Safe49 2012 05

Safe98 2017 04

Plugged filter or hoses can cause overheating to the power source and torch.


Safe45 2012 05

Safe50 2012 05

Safe46 2012 05

During the first 50 hours of operation keep welding load above 200

°

Every 100 hours, check and clean filter and check condition of hoses.

Moving parts can injure.



Read the Owner’s Manual before working on this machine.

Safe46 2012 05

Safe51 2012 05

Safe51 2012 05

Safe70 2012 06



Use coolant suggested by the manufacturer.

ment.

amperes. Do not weld below 200 amperes of output.


Safe46 2012 05

Safe55 2012 05

Safe47 2012 05

Safe52 2012 05

Safe54 2017 04

°

Safe71 2012 06

Move jumper links as shown on inside label to match input voltage at

Read Owner’s Manual. Read labels on unit.

Connect Green Or Green/Yellow grounding conductor to ground terminal first.

Pinch points can injure.

Safe119 2015 05

Safe100 2012 08

Safe120 2015 11

Safe121 2016 04

Safe49 2012 05

Move jumper links as shown on inside label to match input voltage at job site. Include extra length in grounding conductor and connect

OMgrounding conductor first. Connect line input conductors as shown on


Recycle.

and torch.

Wear dry insulating gloves. Do not wear wet or damaged gloves.

Safe49 2012 05

Safe73 2017 04

Safe65 2012 06

Plugged filter or hoses can cause overheating to the power source

Environmental Protection Use Period (China)

Safe57 2017 04

OM-

Safe122 2016 04

Safe103 2012 09

Induction heating can cause injury or burns from hot items such as rings, watches, or parts.

Safe50 2012 05 machine or welding.

Wire

Every 100 hours, check and clean filter and check condition of hoses.

Feed wire between guide pins into drive rolls.

Connect green or green/yellow grounding conductor to ground terminal.


Safe65 2012 06

Safe51 2012 05

Safe52 2012 05

OM°

Induction heating can cause injury or burns from hot items such as rings, watches, or parts.


Safe74 2012 07

Safe52 2012 05

OM-289396 Page 12

°

Falling unit can cause injury. Do not move or operate unit where it could tip.

Safe53 2017 04

OM-

OM-

Safe53 2017 04

OM-

Safe123 2016 06

Safe104 2012 09

Safe124 2017 02

Safe105 2012 09

Safe 106 2012 09

OM-

OM-

�


3-2.

Miscellaneous Symbols And Definitions

Amperes

Water (Coolant)

Output

Cooling Output

Gas Tungsten Arc

Welding (GTAW)

Gas Input

Volts

Input Voltage

Three Phase Static

Frequency Converter-Transformer-

Rectifier

Output Voltage

Gas Output

Rated Welding

Current

Duty Cycle

Direct Current

Remote

Seconds

On

Off

Positive

Negative

Alternating Current

(AC)

Water (Coolant)

Input

Initial Amperage

Rated Cooling

Power (Coolers)

Rated Maximum

Pressure (Coolers)

Increase/Decrease

Of Quantity

Percent

Hertz

Pulse

Line Connection

Pulse Frequency

Conventional Load

Voltage

Process (Welding)

Primary Voltage

Suitable for Welding in an Environment with Increased Risk of Electric Shock

Degree of

Protection

Shielded Metal Arc

Welding (SMAW)

Rated Maximum

Supply Current

Maximum Effective

Supply Current

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

Protective Earth

1-2.

Miscellaneous Symbols And Definitions

Normal Trigger

Operation

(GTAW)

Two-Step Trigger

Operation

(GTAW)

Four-Step Trigger

Operation

(GTAW)

Rated No Load

Voltage (OCV)

Contactor Control

(Stick)

Pulser On-Off

OM-289396 Page 13

OM-270536 Page 4

�


SECTION 4 – SPECIFICATIONS

4-1.

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.

4-2.

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.

4-3.

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.

4-4.

Welding Power Source Specifications

�

This equipment will deliver rated output at an ambient air temperature up to 104° F ( 40° C).

�

Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-6 and 5-5 for information on

connecting input power.

Welding Amperage Range Max Open-Circuit Voltage (U

0

) Low Open-Circuit Voltage (U

0

)

5–300 1 60 8–15 2

Rated Peak Striking Voltage

(U p

)

14KV 3

1

Welding range for Stick process is 5-230 amperes. For TIG, the amperage range is tungsten diameter dependent (see Section 6-5).

2 Low open-circuit voltage while in TIG Lift Arc ™ , or while in Stick with low open-circuit voltage selected.

3 Arc starting device is designed for manual guided operations.

Process

STICK

Current (A)

230

160

125

300

TIG* 210

175

*Includes cooler power draw.

Output Ratings

Voltage (V)

28.4

26.4

25

22

18.4

17

Duty Cycle

30%

60%

100%

30%

60%

100%

Phase

3

3

3

3

3

3

Current Draw (A) At Rated Input Voltages (V)

380V

13.8

400V

12.9

8.7

6.6

13.7

8.2

6.6

8.2

6.3

13.0

7.9

6.3

4-5.

Cooler Specifications

�

The correction factor on the cooling power at an ambient temperature of 104° F ( 40° C) is 0.625.

Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns

Use With Guns/Torches Rated Up To 600 Amperes

Coolant Tank Capacity

Rated Cooling Power

3 gal (11.4 L)

1.42 kW at 1.1 qt/min at 77°F (4,840 BTU/hr at 1 L/min at 25°C)

Input Power kW

8.6

5.4

4.1

8.5

5.1

4.0

kVA

8.9

5.6

4.3

8.9

5.4

4.2

OM-289396 Page 14

�


4-6.

Coolant Specifications

Do not use conductive coolant.

Application

GTAW Or Where High Frequency Current Is Used

Coolant

Low Conductivity Coolant 043810*

Distilled Or Deionized Water Okay Above 32°F (0°C)

*Coolants 043810 and 043809 protect to -37°F (-38°C) and resist algae growth.

NOTICE – Use of any coolant other than those listed in the table voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.).

4-7.

Dimensions, Weights, And Mounting Options

A. Welding Power Source

Dimensions

A

A

B

C

29-3/8 in. (746 mm)

15 in. (381 mm)

24-5/8 in. (625 mm)

B

C

Ref. 805617-A

B. Welding Power Source With Cart And Cooler

Weight

A

A

B

C

101 lb (45.8 kg)

Dimensions

43-7/8 in. (1114 mm)

20-1/2 in. (521 mm)

36 1/4 in. (921 mm)

B

C

Ref. 805617-A

Weight

(Empty)

178 lb (80.1 kg)

OM-289396 Page 15

C. Mounting Options

E

�


Dimensions

A

A B

C

B

D

C

D

805620-A

E

19-1/2 in. (495 mm)

2 in. (51 mm)

4 x .500 in. Dia. (13 mm) Base

1 in. (25 mm)

13 in. (330 mm)

OM-289396 Page 16

�


4-8.

Duty Cycle And Overheating

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

If unit overheats, output stops, a Help mes-

sage is displayed (see Section 8-4), and cool-

ing fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

NOTICE – Exceeding duty cycle can damage machine or torch and void warranty.

TIG

300

250

STICK

200

150

0

10 30

Rated Duty Cycle (%)

60 100

247219-B

Overheating

0 A or V

15

OR

Reduce Duty Cycle

Minutes

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-289396 Page 17

�


4-10. Environmental Specifications

A. IP Rating

IP Rating

IP23

This equipment is designed for outdoor use.

B. Temperature Specifications

Operating Temperature Range *

14 to 104°F (-10 to 40°C)

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

C. Information On Electromagnetic Compatibility (EMC)

Storage/Transportation Temperature Range

-4 to 131°F (-20 to 55°C)

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

1-1.


This equipment complies with IEC61000-3-11 and IEC 61000-3-12 and can be connected to public low-voltage systems provided that the public low-voltage system impedance Z max at the point of common coupling is less than 71.1mΩ (or the short-circuit power S sc is greater than necessary, that the system impedance complies with the impedance restrictions.

D. EU Ecodesign Information

Model

Syncrowave 300 400V Three Phase

Minimum Power Source

Efficiency

81.9%

Maximum Idle State

Power Consumption

21.9 W

Safe1 2012 05


by disposing at a designated collection facility.

Contact your local recycling office or your local distributor for further


Safe37 2017 04

Critical raw materials possibly present in indicative amounts higher than 1 gram at component level

Component

Printed circuit boards

Critical Raw Material

Plastic components

Earth, Niobium, Platinum Group Metals, Scandium, Silicon Metal, Tantalum, Vanadium

Antimony, Baryte

Electrical and electronic components

Metal components

Cables and cable assemblies

Antimony, Beryllium, Magnesium

Beryllium, Cobalt, Magnesium, Tungsten, Vanadium

Display panels

Batteries

Gallium, Indium, Heavy Rare Earth, Light Rare Earth,Niobium, Platinum Group Metals, Scandium

Fluorspar, Heavy Rare Earth, Light Rare Earth, Magnesium

Safe2 2017 04

Safe3 2017 04


Safe4 2017 04


Safe5 2017 04


Safe6 2017 04

OM-289396 Page 18


Safe7 2017 04


Safe8 2012 05


Safe9 2012 05

OM-


�


5-1.

Selecting A Location

1-3.



bel location information to the appropriate sections.

1

1-3.


1

2

3

Do not move or operate unit where it could tip.

Special installation may be required where gasoline or volatile liquids are present - see NEC Article 511 or CEC Section 20.

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to move unit.

If using lifting forks, extend forks beyond opposite side of unit.

3 Line Disconnect Device

4 Running Gear

Locate unit near correct input power supply.

2

3

Location And Airflow

1 3

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

18 in.

(460 mm)

3 loc_large 2018-08

18 in.

(460 mm)

18 in. (460 mm)

18 in. (460 mm) loc_large 2018-08

4

18 in. (460 mm) 18 in. (460 mm)

OM-

OM-289396 Page 19

OM-

�


5-2.

Selecting Cable Sizes

1

NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

Welding Amperes 3

300

350

400

500

100

150

200

250

Weld Cable Size 2 and Total Cable (Copper) Length in Weld Circuit Not Exceeding

100 ft (30 m) or Less 4 150 ft (45 m) 200 ft (60 m)

10 - 60% Duty Cycle

AWG (mm 2 )

4 (20)

60 - 100% Duty Cycle

AWG (mm

4 (20)

2 )

4 (20)

10 - 100% Duty Cycle

AWG (mm 2 )

3 (30)

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

1/0 (60)

2/0(70)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

2/0 (70)

3/0 (95)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95)

4/0 (120)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

4/0 (120)

2x2/0 (2x70)

1 This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

2 Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm 2 for metric use.

3 Select weld cable size for pulsing application at peak amperage value.

4 For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding Society at http://www.aws.org

.

OM-289396 Page 20

3

4

1

2

�


5-3.

Connecting Weld Cables, Remote Control, And Shielding Gas

Front Panel

Turn off power before connecting to weld output terminals.

Do not use worn, damaged, undersized, or repaired cables.

Connections

1 Remote Control Receptacle (See Section

5-7)

2 Electrode Weld Output Terminal

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

For stick (SMAW), connect electrode holder to this terminal.

3 Gas Out Connection

Requires an 11/16 in. wrench.

4 Work Weld Output Terminal

Connect work clamp to this terminal.

5 Gas In Connection

Fitting has 5/8-18 in. right hand threads, and usually requires an 11/16 in. wrench. Maximum pressure is 125 psi (.86 MPa).

Rear Panel

5 allen_wrench allen_set

NGO’s tools/ flathead philips head wrench

11/16 in.

crescent wrench

Ref. 805618-A pliers needlenose knife steelbrush nutdriver chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun file filterwrench paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

OM-289396 Page 21

allen_wrench allen_set pliers needlenose knife

5-4.

Cooler Connections

�


1

2

3

4

5

NGO’s tools/ flathead philips head wrench

11/16 in.

crescent wrench

805619-A

�

Cart and cooler are optional equipment.

1 Electrode Weld Output Terminal

Connect TIG torch to this terminal.

2 Gas Out Connection

Connect TIG torch gas hose to gas out fitting.

3 Work Weld Output Terminal

Connect work lead to this terminal.

4 Water-Out (To Torch) Connection

Connect torch water supply (blue) hose to the coolers water-out connection.

4

5 Water-In (From Torch) Connection

Connect torch water return (red) hose to the coolers water-in connection.


Application GTAW or where HF (high frequency current) is used

Coolant

(3 gal)

Low Conductivity Coolant

043810

� 50/50 solution

� Protects to –37°F

(–38°C)

� Resists algae growth

Distilled or dionized water okay above 32°F (0°C)


steelbrush nutdriver chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun filterwrench

OM-289396 Page 22 file paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�


5-5.

Electrical Service Guide

A. Electrical Service Guide For Three-Phase Operation

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

CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.

NOTICE – INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency ±10%) and voltage ±10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

3-Phase

Rated Supply Voltage (V)

Rated Maximum Supply Current I

1max

(A)

Rated Effective Supply Current I

1eff

(A)

Maximum Recommended Standard Fuse Rating In Amperes 1

Time Delay Fuses 2

Normal Operating Fuses 3

Maximum Recommended Supply Conductor Length In Feet

(Meters) 4

Raceway Installation

Minimum Supply Conductor Size In AWG (mm 2 ) 5

Minimum Grounding Conductor Size In AWG (mm 2 ) 5

Reference: 2020 National Electrical Code (NEC) (including article 630)

380

13.8

7.6

15

20

158 (48)

14 (2.5)

14 (2.5)

400

13.0

7.1

15

20

178 (54)

14 (2.5)

14 (2.5)

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 Maximum total length of copper input conductors in entire installation, raceway and/or flexible cord.

5 Raceway 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 75°C (167°F) with not more than three single current-carrying conductors in a raceway.

OM-289396 Page 23

�


5-6.

Connecting 3-Phase Input Power

3

6

4

1

3

= GND/PE Earth Ground

7 allen_wrench

2

L1

L2

L3

5 allen_set

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.

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

For Three-Phase Operation

1 Input Power Cord

2 Disconnect Device (switch shown in the

OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding Terminal

5 Input Conductors (L1, L2, And L3)

6 Disconnect Device Line Terminals

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

Connect input conductors L1, L2, and L3 to disconnect device line terminals.

7 Over-Current Protection

Select type and size of over-current protection using Electrical Service Guide (fused disconnect switch shown).

NGO’s

Close and secure door on disconnect device.

tools/ dures to put unit in service.

flathead philips head wrench crescent wrench pliers needlenose knife steelbrush nutdriver chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter input2 2012−05 − 803766-C / Ref. 805618-A

OM-289396 Page 24 torque screwdriver torque wrench socket wrench drill greasegun filterwrench handream strapwrench airgun hammer awl file paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�


5-7.

Remote 14 Receptacle Information

Remote 14 Socket

A

B

A

K

C

L

D M

N

E

J

I

F

G

H

15 Volts DC Output

Contactor

Remote Output

Control

Common

B

C

D

E

F

H

G

Socket Information

Contactor control +15 volts DC, referenced to G.

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

Output to remote control; +10 volts DC output to remote control.

Remote control circuit common.

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

Current feedback; +1 volt DC per 100 amps output.

Voltage feedback; +1 volt DC per 10 volts output.

Return for all output signals: F, H, and A.

Chassis K Chassis

805617-A

Sockets G and K are electrically isolated from each other.

�

If a remote hand control like the RHC-14 is connected to the Remote 14 receptacle, some current value above min. must be set on the remote control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote hand control will not function.

2-13. Software Updates

5-8.

Software Updates

A. Reasons For Downloads Of Software Updates

B. Requirements

A. Reasons For Downloads Of Software Updates

B. Requirements

Reasons To Download Software Updates:

� To get the latest feature and software improvements with future software updates.

� For all circuit board replacements, a software update is required to ensure proper unit operation.

� A software update is required to ensure proper software expansion operation of all purchased feature expansions.

1

1

Requirements

2

A computer with an SD memory card port, or

SD memory card reader is required to download software updates.

32 GB max, full size SD memory card required.

The SD logo is a registered trademark of

SD-3C LLC.

How To Download Software Updates

In a web browser, go to www. millerwelds.

com/support/system-setup-and-software/tigsoftware

Click System Installation Instructions

(PDF) and follow the instructions.

2

C. Software Installation

1 2

OM-289396 Page 25

273670-B

C. Software Installation

1 2

273670-B

B. Installing Software Updates

�


Syncrowave 300 Shown

1

2

�

Software updates may reset machine back to default values.

Card Requirements:

32 GB max, full size SD memory card required.

1 Memory Card Port

2 Indicator LED

Insert card containing new software into port while machine is on, but not while welding.

Inserting card while welding will interrupt the welding process.

LED indicator blinks green when machine is reading from or writing to the card, and the meter displays go blank. The update time may vary up to three minutes.

Do Not remove card while LED is blinking green.

After successfully reading from or writing to the card, the LED switches from blinking to continuous green, and the meters illuminate.

The machine is now ready for use.

Ref. 805618-A

Troubleshooting:

Indicator LED is blinking red: Error updating software, or software is not compatible. Try removing and inserting card.

Indicator LED is continuous red: Cannot read card. Card might be bad.

OM-289396 Page 26

�


SECTION 6 – SYNCROWAVE OPERATION

6-1.

Syncrowave Controls

4 7 5 3

1

2

6

9

MENU

PRO-SET

TM

8

1 Main Power Switch

Use switch to turn machine on or off.

2 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 7-1).

3 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 (see Section 5-8).

4 Voltmeter

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

5 Ammeter

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

6 Menu Button

8 Process Selector Control

Use to processes: select one of the

280539-B following

� AC TIG - Used for welding aluminum.

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

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

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

Press button to scroll through available parameters for the selected process. Hold but-

ton to enter set-up mode (see Sections 6-2

thru 7-1).

9 Pro Set Button

7 Output ON Indicator

Blue indicator illuminates when output is on.

Press button to lock in all parameters to factory setting while LED is lit. Press and Hold for 5 seconds to reset all parameters to factory settings. Meter display counts down.

OM-289396 Page 27


3-2.

Accessing Control Panel Menu: AC TIG

2 3 4 1

150A

�


6-2.

Accessing Process Menu: AC TIG

2

Parameter/Setting Display

[BAL] [68%]

3 4

150A

1

247222-D

MENU

PRO-SET

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.

�

Parameter automatically returns to amperage setting 15 seconds after Amperage Adjustment control is inactive.

Amperage Control

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

*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.

280539-B

Balance Control* (%EN)

Description

Controls oxide cleaning.

Increasing setting reduces oxide cleaning. Range is Ball, 60% to 80%.

“Ball” sets the Balance to 30%. This allows the operator to form a ball on the tip of the tungsten. “Ball” is not intended for normal welding operation.

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.


[FSLP] [3T]


[FNL] [10A]


[POST] [AUTO]

OM-270536 Page 17

Final Slope Time

Description

Range is OFF - 50.0T (seconds).

Description

Range is min - 300 amps.

Final Amperage

Post Flow Control

Description

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.

OM-289396 Page 28

�


6-3.

Accessing Process Menu: DC TIG And DC TIG Pulse

2


[PPS] [100]


[FSLP] [3T]


[FNL] [10A]


[POST] [AUTO]

3 4

150A

MENU

PRO-SET

280539-B

1

1 Menu Button


2 Parameter Display

3 Setting Display



�






Description

[PPS]* Pulse Control (DC TIG Pulse Only)

Reduces heat input to minimize distortion and increase travel speed. Set PPS (pulses per second). The range is 0.1-150 PPS. The Background Amperage and Peak Amperage are not adjustable. Background

Amperage equals 25% of Peak amperage. Peak amperage Time equals 40%.

Final Slope Time

Description

Range is OFF - 50.0T (seconds).

Description

Range is min - 300 amps.

Final Amperage

Post Flow Control

Description

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.

OM-289396 Page 29

�


6-4.

Accessing Process Menu: DC Stick

2


[DIG] [30%]

3 4

110A

MENU

PRO-SET

280539-B

1

1 Menu Button


2 Parameter Display

3 Setting Display



�






Arc Force Control*

Description

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%. Features PRO−SET values for 6010 [65%] and 7018 [30%] electrodes.

OM-289396 Page 30

�


6-5.

Accessing User Menu: AC/DC TIG And DC TIG Pulse

2 3 4 1

MENU

MENU

PRO-SET

1 Menu Button

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

2 Parameter Display

3 Setting Display



�

To exit menu, press and hold Menu button until Menu Off is displayed.


[STRT] [HF]

[STRT] [LIFT]


[TUNG] [3/32]


[RMT] [STD]

[RMT] [2T]

[OUT] [ON]

[PRE] [0.2T]

280539-B

Arc Starting Method Selection

Description

High Frequency is a non-contact starting method (see Section 13-1).

Lift Arc is a contact starting method (see Section 13-1).

Tungsten Diameter Selection

Description

Each tungsten size has preset starting parameters specific to that diameter for optimized starting. Range is 0.040 in.−1/8 in. or 1.0 mm−4.0 mm.

Trigger Mode Selection

Description

Typically used with a remote foot or hand control. RMT STD requires a maintained contact closure to enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the control panel.

Remote control required. Allows the operator to weld without holding the trigger closed. To start the weld, operator presses and releases trigger. To stop the weld, the operator again presses and releases the trigger. In this mode, only the output contactor is controlled by the remote control. Amperage must be set on the control panel.

Output on. (Lift Only)

Weld output terminals are energized at all times when displays read [OUT] [ON].

No remote control or trigger required. Amperage can be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates to indicate output is on.

Preflow Time: Controls length of time gas flows prior to arc start. Range is OFF-25T (seconds).

OM-289396 Page 31

�


6-6.

Accessing User Menu: DC Stick

2 3 4 1

USER MENU

MENU

PRO-SET

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.

2 Parameter Display

3 Setting Display



�

To exit menu, press and hold Menu button until Menu Off is displayed.


[RMT] [STD]

[OUT] [ON]

280539-B

Trigger Mode Selection

Description

Typically used with a remote foot or hand control. RMT STD requires a maintained contact closure to enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the control panel.

Output on.

Weld output terminals are energized at all times when displays read [OUT] [ON].

No remote control or trigger required. Amperage can be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates to indicate output is on.

OM-289396 Page 32

�


SECTION 7 – ADVANCED MENU FUNCTIONS

7-1.

Accessing Tech Menu

2 3 4 1

TECH MENU

MENU

PRO-SET

1 Menu Button

Press and hold Menu button for approximately four seconds to scroll past User Menu to Tech Menu. Use Menu button to cycle through parameters that can be set.

2 Parameter Display

3 Setting Display


Rotate amperage adjustment control to adjust parameter setting.

To exit tech 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.

280539-B


[ARC] [T/CY]

[ERR] [LOG]

[COOL] [AUTO]

[MACH] [RSET]

[SOFT] [WARE]

[SERL] [NUM]

Description

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].

Error Log: Use to view last eight logged error events. Each event may list multiple Error Codes. See Sec-

tion 8-5.

Cooler Power (Optional): Selects between [OFF], and [AUTO]. [OFF] disables the power to the cooler.

[AUTO] provides power to the cooler when the TIG process is active.

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.

Software Number: Software number and revision will be displayed.

Serial Number:

If serial number displayed does not match serial number of machine, see Section 8-5

OM-289396 Page 33

�


7-2.

Summary Of Default And Pro-Set Parameters

AC TIG DC TIG DC PULSE TIG STICK

Process Menu Range

Default

(Pro-Set)

Range

[BAL]

Balance

[PPS] Pulses

Per Second

[FSLP]

Slope Down

Time (Seconds)

[FNL]

Final Amperage

(AMPS)

Ball 30%,

60% to 80%

—

Off-50T

Min-Max

Amp

[POST]

Post Flow

Auto, Off,

On 1 to 50

Seconds

[DIG]

Dig Control

User Menu

—

Range

68%

—

3T

10

Auto

—

—

—

Off-50T

Min-Max

Amp

Auto, Off,

On 1 to 50

Seconds

—

Default Range

[STRT]

Start Method

[TUNG]

Tungsten Size

[RMT]

Trigger Mode

HF, Lift

0.40 to 1/8

HF

3/32

HF, Lift

0.40 to 1/8

[PRE]

Pre Flow

2T, On*,

Standard

2T

2T, On*,

Standard

Off,

0.2 to 25

Seconds

0.2 Seconds

Off,

0.2 to 25

Seconds

Tech Menu

[ARC] [T/CY]

Arc Timer

[ERR] [LOG]

Error Log

Range

—

—

Default

—

—

Range

—

—

[COOL]

Cooler Power

[MACH] [RESET]

Machine Reset

[SOFT] [WARE]

Software Number

Auto, On,

Off

—

—

Auto

—

—

Auto, On,

Off

—

—

[SERL] [NUM]

Serial Number

— —

* “On” Trigger Mode only available in Lift Arc Start Method.

OM-289396 Page 34

—

Default

(Pro-Set)

—

—

3T

10

Auto

—

Default

HF

3/32

2T

0.2

Seconds

Default

—

—

Auto

—

—

—

Range

—

0.1 to 150

PPS

Off-50T

Min-Max

Amp

Auto, Off,

On 1 to 50

Seconds

—

Range

HF, Lift

0.40 to 1/8

2T, On*,

Standard

Off,

0.2 to 25

Seconds

Range

—

—

Auto, On,

Off

—

—

—

Default

(Pro-Set)

—

100 PPS

3T

10

Auto

—

Default

HF

3/32

2T

0.2

Seconds

Default

—

—

Auto

—

—

—

Range

—

—

—

—

—

Off to 100%

Range

—

—

On,

Standard

—

Range

—

—

Auto, On,

Off

—

—

—

Default (Pro-

Set)

—

—

—

—

—

30%

Default

—

—

ON

—

Default

—

—

Auto

—

—

—

�


7-3.

Output Control And Trigger Functions

A. Remote (Standard), 2T, Torch Trigger Operation

Current (A)

Current (A)

Current (A)

Initial Slope

Initial Slope

Preflow

Initial Amps

Initial Amps

Time

Time

Standard

Time

Preflow

Preflow

Main Amps

Main Amps

Main Amps

Final Slope

Final Slope

Final Slope

Final Amps

Final Amps

Postflow

Final Amps

Postflow

Postflow

P/H

P/H

R R

Maintained Switch

Remote Control

P/H = Push and hold trigger; R = Release trigger.

�

When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope and final amps are controlled by the remote control, not by the welding power source

Remote 2T

P/R

P/R

P/R

P/R

P/R = Push and release trigger.

�

If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.

P/R

P/R

P/R

P/R

P/R

P/R

*P/R

*P/R

P/R

P/R

OM-289396 Page 35

�


SECTION 8 – MAINTENANCE AND TROUBLESHOOTING

8-1.

Routine Maintenance

Disconnect power before maintaining.

�

Maintain more often during severe conditions.


A. Welding Power Source

SECTION 12 MAINTENANCE AND TROUBLESHOOTING

◇ = Change � = Clean r = Repair � = Replace

3 3

Months

3

Months

!

Disconnect power before maintaining.

Maintain more often during severe conditions.

Labels

� � Labels � � Gas Hoses

A. Welding Power Source 3 3

= Change = Clean

* To be done by Factory Authorized Service Agent

∆

= Repair = Replace = Check

SECTION 9 MAINTENANCE AND TROUBLESHOOTING

Every

3

Months

Every

6

6-1.

Blowing Out Inside of Unit

Months

!

� r �

Every

6

Labels

Months

!

Do not remove case when blowing out inside of unit

Gas Hoses

Every

6

Every

3

Months

∆

Cables And Cords

:During heavy service, clean monthly.


6

� During heavy service, clean monthly.

!



Months

9-1.Optional Cooler

Every

3

Months

= Check

Every 3

Months

� = Change ◇

∆

= Repair = Clean � = Clean

∆

= Repair � = Replace


Every

3

Months clean more frequently.

= Check = Change = Clean

* To be done by Factory Authorized Service Agent

Blow out heat exchanger fins.

Coolant Strainer, clean more frequently.

∆

= Repair

Blow out heat exchanger fins.

Check coolant level. Top off with

distilled or deionized water if necessary.

= Replace

Every

3

Months

� Coolant strainer; during heavy service, clean more frequently.

durning heavy service, clean more frequently.

� Blow out heat exchanger fins.

� Check coolant level. Top off with distilled or deionized water if necessary.

9-2.

9-2.

Blowing Out Inside of Unit

Months

Every

Every

12

Months

� � Hoses Labels �� Labels

!

Do not remove case when blowing out inside of unit.

To blow out unit, direct airflow through front and back louvers as shown.

!


OM-249336 Page 1


◇ Coolant

OM-289396 Page 36

OM-270536 Page 65

805497-A 805497-A

OM-270536 Page 42 OM-270536 Page 42

OM-249336 Page 1

�


8-2.

Blowing Out Inside Of Unit



8-3.

Coolant Maintenance

805621-A

1

Application

Coolant

(3 gal)


GTAW or where HF (high frequency current) is used

Low Conductivity Coolant 043810

� 50/50 solution

� Protects to –37°F

(–38°C)

� Resists algae growth

Distilled or dionized water okay above 32°F (0°C)


Disconnect input power before maintaining.

1 Coolant Filter

Unscrew housing to clean filter.

Changing coolant: Drain coolant by tipping unit to the front, or use suction pump. Fill with clean water and run for 10 minutes.

Drain and refill with coolant.

�

If replacing hoses, use hoses compatible with ethylene glycol, such as

Buna-N, Neoprene, or Hypalon. Oxyacetylene hoses are not compatible with any product containing ethylene glycol.

OM-289396 Page 37

�


8-4.

Voltmeter/Ammeter Display Messages

�

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

Message Type Display Message Description

Release Trigger [RELE] [ASE] /

[TRIG] [GER]

Remote 14 receptacle contactor control (Pins A-B) must be opened before proceeding.

Un Short Output

Over Temperature Error

Latching Error

Not Valid

Software Not Valid

[UN S] [HORT] /

[OUTP] [UT]

[OVER] [TEMP]

When one of the following errors occurs, the Standby LED flashes. To clear error, press Standby button or turn

off power. See Section 8-5 if error does not clear or happens frequently.

[CHEK] [INPT] Check Input: High or low voltage has been sensed. Have a qualified person check input voltage.

[WELD] [CABL]

[SEE] [O.M.]

[COOL] [PWR]

Weld Cable: An error related to the weld cables has been sensed. Straighten out or shorten weld cables.

See Owner’s Manual: See Section 8-5.

Cooler Power: An error related to the power supplied to the cooler, incorrect primary wiring on single phase, or a blown fuse has occurred. When error will not clear or occurs frequently, machine can be used without the cooler. Turn

Cooler Power off (see Section 7-1).

[NOT] [VALD]

[SOFT] [WARE] /

[NOT] [VALD]

Short on weld output connections must be removed before proceeding. See

Section 8-5 if display shows after weld output connections have been verified

as not having a short.

Over temperature condition has occurred. Error will clear after temperatures reach acceptable levels.

Message is displayed when attempting an incompatible setup.

A software compatibility error has been detected. A software update is re-

quired (see Section 5-8). See Section 8-5 if display shows after a software up-

date is performed.

OM-289396 Page 38

�


8-5.

Troubleshooting Table

Trouble

No weld output; unit completely inoperative.

Remedy

Place line disconnect switch in On position (see Section 5-6).

No weld output; meter display On.

Erratic or improper weld output.

Fan not operating.

Wandering arc.

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-6).

Check for proper input power connections (see Section 5-6).

If using remote control, be sure correct process is enabled to provide output control at Remote 14 re-

ceptacle (see Section 5-7 as applicable).

Input voltage outside acceptable range of variation (see Sections 5-5).

Check, repair, or replace remote control.

Unit overheated. Allow unit to cool with fan On (see Section 4-8).

Use proper size and type of weld cable (see Section 5-2).

Clean and tighten all weld connections (see Section 8-1).

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

Use proper size tungsten (see Section 12).

Use properly prepared tungsten (see Section 12).

Reduce gas flow rate.

Shield weld zone from drafts.

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

Blank display.

Error message [ERR] [LOG] is displayed.

Latching Errors (see Section 8-4).

Error message [SEE] [O.M.] is displayed.

Tech Menu (See Section 7-1) [SERL]

[NUM] is selected, and serial number displayed does not match serial number of machine.

Error message [UN S] [HORT] /

[OUTP] [UT] is displayed.

Error message [SOFT] [WARE] [NOT]

[VALD] is displayed.

Increase postflow time.

Check and tighten all gas fittings (see Section 8-1).

Water in torch. Refer to torch manual.

Verify Power to machine.

A software update may be required (see Section 5-8). Contact factory if display remains blank after a

software update is performed.

Contact a Factory Authorized Service Agent for an explanation of the error code.

Contact a Factory Authorized Service Agent if error does not clear or happens frequently.

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent if display shows after weld output connections have been verified as not having a short.

Contact a Factory Authorized Service Agent if display shows after a software update is performed.

OM-289396 Page 39

�


SECTION 9 – PARTS LIST

9-1.

Recommended Spare Parts

Dia. Mkgs. Part No.

239494

043810

Recommended Spare Parts

Description

Screen, Filter Lp Cyl 100x100x0.0045 SST A

Coolant

Quantity

1

1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. Labels available separately or as part of label kit.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-289396 Page 40

SECTION 10 – ELECTRICAL DIAGRAMS

Figure 10-1. Circuit Diagram

284622-C

OM-289396 Page 41

SECTION 11 – HIGH FREQUENCY

SECTION 1 HIGH FREQUENCY

11-1. Welding Processes Requiring High Frequency

SECTION 1 HIGH FREQUENCY

1 High-Frequency Voltage

1

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

1

TIG

TIG

11-2. Installation Showing Possible Sources Of HF Interference

Best Practices Not Followed

13

13

11, 12

11, 12

1

1

9

8

9

8

7

7

10

10

2

2

3

3

4

4

5 6

5 6

14

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

S-0694

OM-289396 Page 42

OM-

OM-

11-3. Recommended Installation To Reduce HF Interference

Best Practices Followed

3 50 ft

(15 m)

50 ft

(15 m)

5

1

6

4

2

8

8

7

9 11

10

8

8

13

12

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.

Ground all metal objects and all wiring in welding zone using #12 AWG wire.

Ground workpiece if required by codes.

9 Nonmetal Building

Metal Building Requirements

10 Metal Building

11 Metal Building Panel Bonding Methods

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

12 Windows and Doorways

Cover all windows and doorways with grounded copper screen of not more than 1/

4 in (6.4 mm) mesh.

13 Overhead Door Track

Ground the track.

OM-289396 Page 43

OM-

SECTION 12 – SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

12-1. Selecting Tungsten Electrode

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

NOTICE – Wear clean gloves to prevent contamination of tungsten.

A. Select Tungsten Electrode

Electrode Diameter

(2% Ceriated or 1.5% Lanthanum Alloy

Tungstens)

Amperage Range By Gas Type* And Polarity

DCEN – Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

0.010 in. (0.25 mm)

0.020 in. (0.50 mm)

0.040 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)

3/16 in. (4.8 mm)

1/4 in. (6.4 mm)

Up to 15

5–20

15–80

70–150

150–200

250–400

400–500

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).

AC – Argon

Unbalanced Wave (75% EN Balance)

(For Use With Aluminum)

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 (Gray)

1.5–2% Lanthanum (Yellow/Blue)

Pure Tungsten (Green)

Application Notes

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

Excellent low amp starts for AC and DC welding.

Not recommended for inverters!

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

�

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.

OM-289396 Page 44

1-1.

Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines

12-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC

Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety

Welding With Inverter Machines

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.

Wrong Tungsten Preparation — Radial Grinding Causes Wandering Arc

Better Tungsten Preparation — Stable Arc

° °

6

Best Tungsten Preparation — Dedicated Tungsten Grinder

2

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use appropriate local exhaust (forced ventilation) at the grinder or wear an approved respi-

4 tion. Properly dispose of grinder dust in an environmentally safe

15

°

30

° away.

Do not use thoriated tungsten. Use tungsten containing ceria, lantha-

Grinding dust from thoriated electrodes contains low-level radioactive material.

�

It is recommended to prepare tungsten with a tungsten grinder designed for that purpose whenever possible.

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.

5 1–1/2 to 4 Times Electrode Diameter

6 Straight Ground Tip

�

Blunting the tip of the electrode is sometimes done to help maintain consistent geometry and resist tungsten erosion. This is especially helpful in AC when melt-back of the tungsten electrode is common.

OM-289396 Page 45

OM-

SECTION 5 TIG PROCEDURES

SECTION 13 – TIG PROCEDURES

SECTION 5 TIG PROCEDURES

5-1.

Lift-Arc And HF TIG Start Procedures

13-1. Lift-Arc And HF TIG Start Procedures

5-1.

Lift-Arc And HF TIG Start Procedures

Lift-Arc Start Method

“Touch” 1–2 Seconds

Do NOT Strike Like A Match!

1 2

Lift-Arc Start

When Lift-Arc ™ follows: button light is On, start arc as

1 TIG Electrode

2 Workpiece

Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control.

Hold electrode to workpiece for 1-

2 seconds , and slowly lift electrode. Arc is formed when electrode is lifted.

Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solidstate output contactor does not energize until after electrode is touching workpiece. This allows a properly prepared electrode (see

Section 12) to touch workpiece without over-

heating, sticking, or getting contaminated.

Application:

Lift-Arc is used for the DCEN or AC GTAW process when HF Start method is not permitted, or to replace the scratch method.

HF Start

When HF Start button light is On, start arc as follows:

High frequency turns on to start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF start is used for the DCEN GTAW, or the

AC GTAW process when a non-contact arc starting method is required.

OM-289396 Page 46

OM-275857 Page 17

OM-275857 Page 17

OM-275857 Page 17

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

1/8

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

3/32

1/8

5/32

3/16

7/32

1/4

1/16

5/64

3/32

1/8

5/32

3/16

7/32

1/4

3/32

3/32

1/8

5/32

3/16

3/32

1/8

5/32

SECTION 14 – STICK WELDING (SMAW) GUIDELINES

14-1. Electrode And Amperage Selection Chart

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

7024

NI-CL

308L

EP,EN

EP

EP

FLAT

HORIZ*

ALL

ALL

LOW

LOW

LOW

SMOOTH, EASY,

FASTER

CAST IRON

STAINLESS

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

OM-289396 Page 47

OM-

Notes

Effective January 1, 2022 (Equipment with a serial number preface of NC or newer)

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

LIMITED WARRANTY - Subject to the terms and conditions below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to authorized distributors that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN

LIEU OF ALL OTHER WARRANTIES, EXPRESS

OR IMPLIED, INCLUDING THE WARRANTIES

OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Notifications submitted as online warranty claims must provide detailed descriptions of the fault and troubleshooting steps taken to diagnose failed parts.

Warranty claims that lack the required information as defined in the Miller Service Operation Guide

(SOG) may be denied by Miller.

Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods listed below. Warranty time periods start on the delivery date of the equipment to the end-user purchaser, or 12 months after the equipment is shipped to a

US or Canada distributor, or 18 months after the equipment is shipped to an international distributor, whichever occurs first.

1 5 Years Parts — 3 Years Labor

� Original Main Power Rectifiers Only to Include

SCRs, Diodes, and Discrete Rectifier Modules in non-inverter products

2 3 Years — Parts and Labor Unless Specified

� Auto-Darkening Helmet Lenses (No Labor)

� Engine Driven Welder/Generators (Including

EnPak) (NOTE: Engines are Warranted

Separately by the Engine Manufacturer.)

� Insight Welding Intelligence Products (Except

External Sensors)

� Inverter Power Sources

� Plasma Arc Cutting Power Sources

� Process Controllers

� Semi-Automatic and Automatic Wire Feeders

� Transformer/Rectifier Power Sources

3 2 Years — Parts and Labor

� Auto-Darkening Weld Masks (No Labor)

� Fume Extractors - Capture 5 and Industrial

Collector Series

4 1 Year — Parts and Labor Unless Specified

� ArcReach Heater

� AugmentedArc, LiveArc, and MobileArc Welding Systems

� Automatic Motion Devices

� Bernard BTB Air-Cooled MIG Guns (No

Labor)

� CoolBelt, PAPR Blower, and PAPR Face

Shield (No Labor)

� Desiccant Air Dryer System

� Field Options (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

� RFCS Foot Controls (Except RFCS-RJ45)

� Fume Extractors - Filtair 130, MWX and SWX

Series, ZoneFlow Extraction Arms and Motor

Control Box

� HF Units

� ICE/XT Plasma Cutting Torches (No Labor)

� Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted

Separately by the Manufacturer.)

� Insight Sensors

� Load Banks

� Motor-Driven Guns (except Spoolmate

Spoolguns)

� Positioners and Controllers

� Racks (For Housing Multiple Power Sources)

� Running Gear/Trailers

� Subarc Wire Drive Assemblies

� Supplied Air Respirator (SAR) Boxes and

Panels

� TIG Torches (No Labor)

� Tregaskiss Guns (No Labor)

� Water Cooling Systems

� Wireless Remote Foot/Hand Controls and

Receivers

� Work Stations/Weld Tables (No Labor)

5 6 Months — Parts

� 12 Volt Automotive-Style Batteries

6 90 Days — Parts

� Accessories (Kits)

� ArcReach Heater Quick Wrap and Air Cooled

Cables

� Canvas Covers

� Induction Heating Coils and Blankets, Cables, and Non-Electronic Controls

� MDX Series MIG Guns

� M-Guns

� MIG Guns, Subarc (SAW) Torches, and External Cladding Heads

� Remote Controls and RFCS-RJ45

� Replacement Parts (No labor)

� Spoolmate Spoolguns

Miller’s True Blue ® to:

Limited Warranty shall not apply

1.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories.

These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

4. Defects caused by accident, unauthorized repair, or improper testing.

MILLER PRODUCTS ARE INTENDED FOR

COMMERCIAL AND INDUSTRIAL USERS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at

Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Miller, (3) the pre-approved cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon use). Products may not be returned without Miller’s written approval. Return shipment shall be at customer’s risk and expense.

The above remedies are F. O. B. Appleton, WI, or

Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO

THE EXTENT PERMITTED BY LAW, THE REM-

EDIES HEREIN ARE THE SOLE AND EXCLU-

SIVE REMEDIES REGARDLESS OF THE LEGAL

THEORY. IN NO EVENT SHALL MILLER BE LI-

ABLE FOR DIRECT, INDIRECT, SPECIAL, INCI-

DENTAL OR CONSEQUENTIAL DAMAGES

(INCLUDING LOSS OF PROFIT) REGARDLESS

OF THE LEGAL THEORY. ANY WARRANTY NOT

PROVIDED HEREIN AND ANY IMPLIED WAR-

RANTY, GUARANTY, OR REPRESENTATION, IN-

CLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTIC-

ULAR PURPOSE, ARE EXCLUDED AND DIS-

CLAIMED BY MILLER.

Some US states do not allow limiting the duration of an implied warranty or the exclusion of certain damages, so the above limitations may not apply to you. This warranty provides specific legal rights, and other rights may be available depending on your state. In Canada, some provinces provide additional warranties or remedies, and to the extent the law prohibits their waiver, the limitations set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary by province.

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives you...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? The expertise of the distributor and Miller is there to help you, every step of the way.

Owner’s Record

Please complete and retain with your personal records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Protective Equipment (PPE)

Service and Repair Replacement Parts

Training (Schools, Videos, Books)

Welding Process Handbooks

To locate a Distributor or Service Agency visit www.millerwelds.com

or call 1-800-4-A-Miller

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

Miller Electric Mfg. LLC

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: 920-735-4505

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

For International Locations Visit www.MillerWelds.com

ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-05

No results