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OM-217 655E 200701

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Arc Welding Power Source

CST 280 And


CST 280 VRD International

Visit our website at File: Stick (SMAW)


www.MillerWelds.com

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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 dont have time to do
it any other way.
Thats 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 couldnt 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. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
Weve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line


of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05

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TABLE OF CONTENTS

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


1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utiliss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3. Stick (SMAW) Volt-Ampere Curves CST 280 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-4. TIG (GTAW) Volt-Ampere Curve CST 280 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-5. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-6. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-7. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-8. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-9. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-10. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-12. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-13. Selecting 400 - 575 Volts AC Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-14. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-15. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-2. Process Select Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-3. Stick Start Procedure Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-5. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-7. Fan-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-8. Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 6 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPTIONS AND ACCESSORIES
WARRANTY

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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
 Warning: Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage


Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

This group of symbols means Warning! Watch Out! possible


 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
 Means Note; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards


 The symbols shown below are used throughout this manual to  Turn off all equipment when not in use.
call attention to and identify possible hazards. When you see  Do not use worn, damaged, undersized, or poorly spliced cables.
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only  Do not drape cables over your body.
a summary of the more complete safety information found in  If earth grounding of the workpiece is required, ground it directly
the Safety Standards listed in Section 1-5. Read and follow all with a separate cable.
Safety Standards.  Do not touch electrode if you are in contact with the work, ground,
 Only qualified persons should install, operate, maintain, and or another electrode from a different machine.
repair this unit.  Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
 During operation, keep everybody, especially children, away.
present.
 Use only well-maintained equipment. Repair or replace damaged
ELECTRIC SHOCK can kill. parts at once. Maintain unit according to manual.
 Wear a safety harness if working above floor level.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is  Keep all panels and covers securely in place.
electrically live whenever the output is on. The input  Clamp work cable with good metal-to-metal contact to workpiece
power circuit and machine internal circuits are also or worktable as near the weld as practical.
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the  Insulate work clamp when not connected to workpiece to prevent
welding wire are electrically live. Incorrectly installed or improperly contact with any metal object.
grounded equipment is a hazard.  Do not connect more than one electrode or work cable to any
 Do not touch live electrical parts. single weld output terminal.
 Wear dry, hole-free insulating gloves and body protection.
SIGNIFICANT DC VOLTAGE exists in inverter-type
 Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
welding power sources after removal of input
or ground. power.
 Do not use AC output in damp areas, if movement is confined, or if  Turn Off inverter, disconnect input power, and discharge input
there is a danger of falling. capacitors according to instructions in Maintenance Section
 Use AC output ONLY if required for the welding process. before touching any parts.
 If AC output is required, use remote output control if present on FUMES AND GASES can be hazardous.
unit.
 Additional safety precautions are required when any of the follow-
Welding produces fumes and gases. Breathing
ing electrically hazardous conditions are present: in damp these fumes and gases can be hazardous to your
locations or while wearing wet clothing; on metal structures such health.
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-  Keep your head out of the fumes. Do not breathe the fumes.
able or accidental contact with the workpiece or ground. For these  If inside, ventilate the area and/or use local forced ventilation at the
conditions, use the following equipment in order presented: 1) a arc to remove welding fumes and gases.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
 If ventilation is poor, wear an approved air-supplied respirator.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder  Read and understand the Material Safety Data Sheets (MSDSs)
is recommended. And, do not work alone! and the manufacturers instructions for metals, consumables,
 Disconnect input power or stop engine before installing or coatings, cleaners, and degreasers.
servicing this equipment. Lockout/tagout input power according to  Work in a confined space only if it is well ventilated, or while
OSHA 29 CFR 1910.147 (see Safety Standards). wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
 Properly install and ground this equipment according to its
lower the oxygen level causing injury or death. Be sure the breath-
Owners Manual and national, state, and local codes.
ing air is safe.
 Always verify the supply ground check and be sure that input  Do not weld in locations near degreasing, cleaning, or spraying op-
power cord ground wire is properly connected to ground terminal in erations. The heat and rays of the arc can react with vapors to form
disconnect box or that cord plug is connected to a properly highly toxic and irritating gases.
grounded receptacle outlet.
 Do not weld on coated metals, such as galvanized, lead, or
 When making input connections, attach proper grounding conduc- cadmium plated steel, unless the coating is removed from the weld
tor first double-check connections. area, the area is well ventilated, and while wearing an air-supplied
 Frequently inspect input power cord for damage or bare wiring respirator. The coatings and any metals containing these elements
replace cord immediately if damaged bare wiring can kill. can give off toxic fumes if welded.
OM-217 655 Page 1

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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense  Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays  Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
 Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
 Wear approved safety glasses with side shields under your
helmet.  Do not touch hot parts bare handed.
 Allow cooling period before working on gun or
 Use protective screens or barriers to protect others from flash,
torch.
glare and sparks; warn others not to watch the arc.
 To handle hot parts, use proper tools and/or
 Wear protective clothing made from durable, flame-resistant mate-
wear heavy, insulated welding gloves and
rial (leather, heavy cotton, or wool) and foot protection.
clothing to prevent burns.

WELDING can cause fire or explosion.


MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks  Pacemaker wearers keep away.
can fly off from the welding arc. The flying sparks, hot  Wearers should consult their doctor before
workpiece, and hot equipment can cause fires and going near arc welding, gouging, or spot
burns. Accidental contact of electrode to metal objects can cause welding operations.
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. NOISE can damage hearing.
 Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
 Protect yourself and others from flying sparks and hot metal. damage hearing.
 Be alert that welding sparks and hot materials from welding can  Wear approved ear protection if noise level is
easily go through small cracks and openings to adjacent areas. high.
 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. CYLINDERS can explode if damaged.
 Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see Shielding gas cylinders contain gas under high
Safety Standards). pressure. If damaged, a cylinder can explode. Since
 Connect work cable to the work as close to the welding area as gas cylinders are normally part of the welding
practical to prevent welding current from traveling long, possibly process, be sure to treat them carefully.
unknown paths and causing electric shock, sparks, and fire  Protect compressed gas cylinders from excessive heat, mechani-
hazards. cal shocks, physical damage, slag, open flames, sparks, and arcs.
 Do not use welder to thaw frozen pipes.  Install cylinders in an upright position by securing to a stationary
 Remove stick electrode from holder or cut off welding wire at support or cylinder rack to prevent falling or tipping.
contact tip when not in use.  Keep cylinders away from any welding or other electrical circuits.
 Wear oil-free protective garments such as leather gloves, heavy  Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap.
 Never allow a welding electrode to touch any cylinder.
 Remove any combustibles, such as a butane lighter or matches,
 Never weld on a pressurized cylinder explosion will result.
from your person before doing any welding.
 Use only correct shielding gas cylinders, regulators, hoses, and fit-
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
tings designed for the specific application; maintain them and
for hot work and have a fire watcher and extinguisher nearby.
associated parts in good condition.
 Turn face away from valve outlet when opening cylinder valve.
FLYING METAL can injure eyes.  Keep protective cap in place over valve except when cylinder is in
use or connected for use.
 Welding, chipping, wire brushing, and grinding  Use the right equipment, correct procedures, and sufficient num-
cause sparks and flying metal. As welds cool, ber of persons to lift and move cylinders.
they can throw off slag.
 Read and follow instructions on compressed gas cylinders,
 Wear approved safety glasses with side associated equipment, and Compressed Gas Association (CGA)
shields even under your welding helmet. publication P-1 listed in Safety Standards.

OM-217 655 Page 2

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

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.


 Do not install or place unit on, over, or near  Keep away from moving parts such as fans.
combustible surfaces.  Keep all doors, panels, covers, and guards
 Do not install unit near flammables. closed and securely in place.
 Do not overload building wiring be sure power supply system is  Have only qualified persons remove doors,
properly sized, rated, and protected to handle this unit. panels, covers, or guards for maintenance as
necessary.
 Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
FALLING UNIT can cause injury.
 Use lifting eye to lift unit only, NOT running READ INSTRUCTIONS.
gear, gas cylinders, or any other accessories.
 Use equipment of adequate capacity to lift and  Read Owners Manual before using or servic-
support unit. ing unit.
 If using lift forks to move unit, be sure forks are  Use only genuine Miller/Hobart replacement
long enough to extend beyond opposite side of parts.
unit.

H.F. RADIATION can cause interference.

OVERUSE can cause OVERHEATING  High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
 Allow cooling period; follow rated duty cycle. communications equipment.
 Reduce current or reduce duty cycle before  Have only qualified persons familiar with
starting to weld again. electronic equipment perform this installation.
 Do not block or filter airflow to unit.  The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
 If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
 Have the installation regularly checked and maintained.
 Put on grounded wrist strap BEFORE handling  Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
 Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

ARC WELDING can cause interference.


MOVING PARTS can cause injury.  Electromagnetic energy can interfere with
sensitive electronic equipment such as
 Keep away from moving parts. computers and computer-driven equipment
 Keep away from pinch points such as drive such as robots.
rolls.  Be sure all equipment in the welding area is
electromagnetically compatible.
 To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can cause injury.  Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
 Do not press gun trigger until instructed to do  Be sure this welding machine is installed and grounded
so. according to this manual.
 Do not point gun toward any part of the body,  If interference still occurs, the user must take extra measures
other people, or any metal when threading such as moving the welding machine, using shielded cables,
welding wire. using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings


 Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause  Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
 Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of  Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
OM-217 655 Page 3

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1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
from Global Engineering Documents (phone: 1-877-413-5184, website: 8004636727 or in Toronto 4167474044, website: www.csain-
www.global.ihs.com). ternational.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard ANSI Standard Z87.1, from American National Standards Institute, 11
AWS F4.1 from Global Engineering Documents (phone: West 42nd Street, New York, NY 100368002 (phone: 2126424900,
1-877-413-5184, website: www.global.ihs.com). website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
022699101 (phone: 6177703000, website: www.nfpa.org). P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:
6177703000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway, OSHA, Occupational Safety and Health Standards for General Indus-
Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
site: www.cganet.com). and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Officesphone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale 3123532220,website: www.osha.gov).

1-6. EMF Information


Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: The body of evidence, in the
tor as practical.
committees judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard. 5. Connect work clamp to workpiece as close to the weld as possi-
However, studies are still going forth and evidence continues to be
ble.
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when About Pacemakers:
welding or cutting. Pacemaker wearers consult your doctor before welding or going near
To reduce magnetic fields in the workplace, use the following welding operations. If cleared by your doctor, then following the above
procedures: procedures is recommended.

OM-217 655 Page 4

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SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
som _3/05
 Avertissement : se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss


Symbole graphique davertissement ! Attention ! Cette pro-
cdure comporte des risques possibles ! Les dangers ven-
tuels sont reprsents par les symboles graphiques joints.

 Indique un message de scurit particulier Ce groupe de symboles signifie Avertissement ! Attention ! Risques
dLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions affrentes
ci-dessous concernant les mesures prendre pour supprimer
 Signifie NOTE ; nest pas relatif la scurit. les dangers.

2-2. Dangers relatifs au soudage larc


 Les symboles reprsents ci-dessous sont utiliss dans ce manuel  Vrifier frquemment le cordon dalimentation afin de sassurer quil
pour attirer lattention et identifier les dangers possibles. En nest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nu
prsence de lun de ces symboles, prendre garde et suivre les peut entraner la mort.
instructions affrentes pour viter tout risque. Les instructions en  Lquipement doit tre hors tension lorsquil nest pas utilis.
matire de scurit indiques ci-dessous ne constituent quun  Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante
sommaire des instructions de scurit plus compltes fournies ou mal pisss.
dans les normes de scurit numres dans la Section 2-5. Lire et  Ne pas enrouler les cbles autour du corps.
observer toutes les normes de scurit.
 Si la pice soude doit tre mise la terre, le faire directement avec un
 Seul un personnel qualifi est autoris installer, faire fonction- cble distinct.
ner, entretenir et rparer cet appareil.  Ne pas toucher llectrode quand on est en contact avec la pice, la terre
 Pendant le fonctionnement, maintenir distance toutes les per- ou une lectrode provenant dune autre machine.
sonnes, notamment les enfants de lappareil.  Ne pas toucher des porte lectrodes connects deux machines en
mme temps cause de la prsence dune tension vide double.
UNE DCHARGE LECTRIQUE peut  Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-
entraner la mort. champ les pices endommages. Entretenir lappareil conformment
ce manuel.
Le contact dorganes lectriques sous tension peut  Porter un harnais de scurit si lon doit travailler au-dessus du sol.
provoquer des accidents mortels ou des brlures
graves. Le circuit de llectrode et de la pice est  Sassurer que tous les panneaux et couvercles sont correctement en
sous tension lorsque le courant est dlivr la place.
sortie. Le circuit dalimentation et les circuits internes de la machine  Fixer le cble de retour de faon obtenir un bon contact mtal-mtal
sont galement sous tension lorsque lalimentation est sur Marche. avec la pice souder ou la table de travail, le plus prs possible de la
Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc de soudure.
commande du rouleau et toutes les parties mtalliques en contact  Isoler la pince de masse quand pas mis la pice pour viter le contact
avec le fil sont sous tension lectrique. Un quipement install ou mis avec tout objet mtallique.
la terre de manire incorrecte ou impropre constitue un danger.  Ne pas raccorder plus dune lectrode ou plus dun cble de masse
une mme borne de sortie de soudage.
 Ne pas toucher aux pices lectriques sous tension.
 Porter des gants isolants et des vtements de protection secs et sans
Il reste une TENSION DC NON NGLIGEABLE dans
trous. les sources de soudage onduleur quand on a coup
 Sisoler de la pice couper et du sol en utilisant des housses ou des lalimentation.
tapis assez grands afin dviter tout contact physique avec la pice  Arrter les convertisseurs, dbrancher le courant lectrique et
couper ou le sol. dcharger les condensateurs dalimentation selon les instructions indi-
 Ne pas se servir de source lectrique courant lectrique dans les zo- ques dans la partie Entretien avant de toucher les pices.
nes humides, dans les endroits confins ou l o on risque de tomber. LES FUMES ET LES GAZ peuvent
 Se servir dune source lectrique courant lectrique UNIQUEMENT si tre dangereux.
le procd de soudage le demande.
 Si lutilisation dune source lectrique courant lectrique savre n- Le soudage gnre des fumes et des gaz. Leur
cessaire, se servir de la fonction de tlcommande si lappareil en est inhalation peut tre dangereuse pour la sant.
quip.
 Dautres consignes de scurit sont ncessaires dans les conditions  Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces va-
suivantes : risques lectriques dans un environnement humide ou si lon peurs.
porte des vtements mouills ; sur des structures mtalliques telles que  lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau de
sols, grilles ou chafaudages ; en position coince comme assise, ge- larc pour lvacuation des fumes et des gaz de soudage.
noux ou couche ; ou sil y a un risque lev de contact invitable ou  Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approu-
accidentel avec la pice souder ou le sol. Dans ces conditions, utiliser v.
les quipements suivants, dans lordre indiqu : 1) un poste souder DC  Lire et comprendre les spcifications de scurit des matriaux (MSDS) et
tension constante ( fil), 2) un poste souder DC manuel (lectrode) les instructions du fabricant concernant les mtaux, les consommables, les
ou 3) un poste souder AC tension vide rduite. Dans la plupart des revtements, les nettoyants et les dgraisseurs.
situations, lutilisation dun poste souder DC fil tension constante  Travailler dans un espace ferm seulement sil est bien ventil ou en
est recommande. En outre, ne pas travailler seul ! portant un respirateur alimentation dair. Demander toujours un sur-
 Couper lalimentation ou arrter le moteur avant de procder veillant dment form de se tenir proximit. Des fumes et des gaz de
linstallation, la rparation ou lentretien de lappareil. Dverrouiller soudage peuvent dplacer lair et abaisser le niveau doxygne provo-
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de quant des blessures ou des accidents mortels. Sassurer que lair de
scurit). respiration ne prsente aucun danger.
 Installer le poste correctement et le mettre la terre convenablement  Ne pas souder dans des endroits situs proximit doprations de d-
selon les consignes du manuel de loprateur et les normes nationales, graissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de
provinciales et locales. larc peuvent ragir en prsence de vapeurs et former des gaz haute-
ment toxiques et irritants.
 Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurer  Ne pas souder des mtaux munis dun revtement, tels que lacier gal-
que le fil de terre du cordon dalimentation est bien raccord la borne vanis, plaqu en plomb ou au cadmium moins que le revtement nait
de terre du sectionneur ou que la fiche du cordon est raccorde une t enlev dans la zone de soudure, que lendroit soit bien ventil et en
prise correctement mise la terre. portant un respirateur alimentation dair. Les revtements et tous les
 En effectuant les raccordements dentre, fixer dabord le conducteur mtaux renfermant ces lments peuvent dgager des fumes toxi-
de mise la terre appropri et contre-vrifier les connexions. ques en cas de soudage.
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LES RAYONS DARC peuvent entra- LES ACCUMULATIONS DE GAZ
ner des brlures aux yeux et la peau. risquent de provoquer des blessures
Le rayonnement de larc du procd de soudage ou mme la mort.
gnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-  Fermer lalimentation du gaz protecteur en cas
quer des brlures dans les yeux et sur la peau. de non-utilisation.
Des tincelles sont projetes pendant le soudage.  Veiller toujours bien arer les espaces confi-
ns ou se servir dun respirateur dadduction
 Porter un casque de soudage approuv muni de verres filtrants ap- dair homologu.
propri pour protger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 numr dans les normes de scurit).
 Porter des lunettes de scurit avec crans latraux mme sous vo- DES PICES CHAUDES peuvent
tre casque.
provoquer des brlures graves.
 Avoir recours des crans protecteurs ou des rideaux pour
protger les autres contre les rayonnements les blouissements et  Ne pas toucher des parties chaudes mains
les tincelles ; prvenir toute personne sur les lieux de ne pas nues.
regarder larc.  Prvoir une priode de refroidissement avant
 Porter des vtements confectionns avec des matires rsistantes dutiliser le pistolet ou la torche.
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.  Ne pas toucher aux pices chaudes, utiliser les outils recom-
mands et porter des gants de soudage et des vtements pais
LE SOUDAGE peut provoquer un pour viter les brlures.
incendie ou une explosion.
Le soudage effectu sur des conteneurs ferms tels
que des rservoirs, tambours ou des conduites peut LES CHAMPS MAGNTIQUES peuvent
provoquer leur clatement. Des tincelles peuvent affecter les stimulateurs cardiaques.
tre projetes de larc de soudure. La projection  Porteurs de stimulateur cardiaque, rester
dtincelles, des pices chaudes et des quipements chauds peuvent
provoquer des incendies et des brlures. Le contact accidentel de distance.
llectrode avec des objets mtalliques peut provoquer des tincelles,  Les porteurs dun stimulateur cardiaque doi-
une explosion, une surchauffe ou un incendie. Avant de commencer vent dabord consulter leur mdecin avant de
le soudage, vrifier et sassurer que lendroit ne prsente pas de sapprocher des oprations de soudage larc,
danger. de gougeage ou de soudage par points.
 Dplacer toutes les substances inflammables une distance de
10,7 m de larc de soudage. En cas dimpossibilit, les recouvrir soi- LE BRUIT peut endommager loue.
gneusement avec des protections homologues.
 Ne pas souder dans un endroit o des tincelles peuvent tomber sur Le bruit des processus et des quipements peut
des substances inflammables. affecter loue.
 Se protger, ainsi que toute autre personne travaillant sur les lieux,  Porter des protections approuves pour les
contre les tincelles et le mtal chaud.
oreilles si le niveau sonore est trop lev.
 Des tincelles et des matriaux chauds du soudage peuvent
facilement passer dans dautres zones en traversant de petites
fissures et des ouvertures.
 Afin dliminer tout risque de feu, tre vigilant et garder toujours un
LES BOUTEILLES peuvent exploser
extincteur la porte de main. si elles sont endommages.
 Le soudage effectu sur un plafond, plancher, paroi ou sparation Des bouteilles de gaz protecteur contiennent du gaz
peut dclencher un incendie de lautre ct. sous haute pression. Si une bouteille est endomma-
 Ne pas effectuer le soudage sur des conteneurs ferms tels que des ge, elle peut exploser. Du fait que les bouteilles de
rservoirs, tambours, ou conduites, moins quils naient t prpa- gaz font normalement partie du procd de soudage,
rs correctement conformment AWS F4.1 (voir les normes de les manipuler avec prcaution.
scurit).
 Brancher le cble de masse sur la pice le plus prs possible de la  Protger les bouteilles de gaz comprim dune chaleur excessi-
zone de soudage pour viter le transport du courant sur une longue ve, des chocs mcaniques, des dommages physiques, du lai-
distance par des chemins inconnus ventuels en provoquant des tier, des flammes ouvertes, des tincelles et des arcs.
risques dlectrocution, dtincelles et dincendie.  Placer les bouteilles debout en les fixant dans un support sta-
 Ne pas utiliser le poste de soudage pour dgeler des conduites tionnaire ou dans un porte-bouteilles pour les empcher de tom-
geles. ber ou de se renverser.
 En cas de non-utilisation, enlever la baguette dlectrode du porte-  Tenir les bouteilles loignes des circuits de soudage ou autres
lectrode ou couper le fil la pointe de contact. circuits lectriques.
 Porter des vtements de protection exempts dhuile tels que des  Ne jamais placer une torche de soudage sur une bouteille gaz.
gants en cuir, une veste rsistante, des pantalons sans revers, des  Une lectrode de soudage ne doit jamais entrer en contact avec
bottes et un casque. une bouteille.
 Avant de souder, retirer toute substance combustible de ses poches  Ne jamais souder une bouteille pressurise risque dexplosion.
telles quun allumeur au butane ou des allumettes.  Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,
 Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B tuyaux et raccords convenables pour cette application spcifi-
pour travaux de soudage et prvoir un dtecteur dincendie et un ex- que ; les maintenir ainsi que les lments associs en bon tat.
tincteur proximit.  Dtourner votre visage du dtendeur-rgulateur lorsque vous
ouvrez la soupape de la bouteille.
DES PARTICULES VOLANTES  Le couvercle du dtendeur doit toujours tre en place, sauf lors-
peuvent blesser les yeux. que la bouteille est utilise ou quelle est relie pour usage ult-
rieur.
 Le soudage, lcaillement, le passage de la
pice la brosse en fil de fer, et le meulage  Utiliser les quipements corrects, les bonnes procdures et suf-
gnrent des tincelles et des particules fisamment de personnes pour soulever et dplacer les bouteil-
les.
mtalliques volantes. Pendant la priode de
refroidissement des soudures, elles risquent  Lire et suivre les instructions sur les bouteilles de gaz comprim,
de projeter du laitier. lquipement connexe et le dpliant P-1 de la CGA (Compressed
Gas Association) mentionn dans les principales normes de scuri-
 Porter des lunettes de scurit avec crans latraux ou un cran t.
facial.

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2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLO- DES ORGANES MOBILES peuvent


SION. provoquer des blessures.
 Ne pas placer lappareil sur, au-dessus ou  Sabstenir de toucher des organes mobiles tels
proximit de surfaces inflammables. que des ventilateurs.
 Ne pas installer lappareil proximit de  Maintenir ferms et verrouills les portes,
produits inflammables. panneaux, recouvrements et dispositifs de
 Ne pas surcharger linstallation lectrique sassurer que protection.
lalimentation est correctement dimensionne et protge avant  Seules des personnes qualifies sont autorises enlever les
de mettre lappareil en service. portes, panneaux, recouvrements ou dispositifs de protection
pour lentretien.
 Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand lentretien est termin et avant de rebrancher
LA CHUTE DE LAPPAREIL peut lalimentation lectrique.
blesser.
 Utiliser lanneau de levage uniquement pour LIRE LES INSTRUCTIONS.
soulever lappareil, NON PAS les chariots, les  Lire le manuel dutilisation avant dutiliser ou
bouteilles de gaz ou tout autre accessoire. dintervenir sur lappareil.
 Utiliser un quipement de levage de capacit  Utiliser uniquement des pices de rechange
suffisante pour lever lappareil. Miller/Hobart.
 En utilisant des fourches de levage pour dplacer lunit, sassu-
rer que les fourches sont suffisamment longues pour dpasser
du ct oppos de lappareil. LE RAYONNEMENT HAUTE
FRQUENCE (HF) risque de provoquer
des interfrences.
LEMPLOI EXCESSIF peut SUR-  Le rayonnement haute frquence (HF) peut
CHAUFFER LQUIPEMENT. provoquer des interfrences avec les quipe-
 Prvoir une priode de refroidissement ; ments de radio-navigation et de communica-
respecter le cycle opratoire nominal. tion, les services de scurit et les ordinateurs.
 Rduire le courant ou le facteur de marche  Demander seulement des personnes qualifies familiarises
avant de poursuivre le soudage. avec des quipements lectroniques de faire fonctionner linstal-
lation.
 Ne pas obstruer les passages dair du poste.
 Lutilisateur est tenu de faire corriger rapidement par un lectri-
cien qualifi les interfrences rsultant de linstallation.
 Si le FCC signale des interfrences, arrter immdiatement
LES CHARGES LECTROSTATIQUES lappareil.
peuvent endommager les circuits  Effectuer rgulirement le contrle et lentretien de linstallation.
imprims.  Maintenir soigneusement ferms les portes et les panneaux des
sources de haute frquence, maintenir les clateurs une
 tablir la connexion avec la barrette de terre distance correcte et utiliser une terre et un blindage pour rduire
avant de manipuler des cartes ou des pices. les interfrences ventuelles.
 Utiliser des pochettes et des botes antistati-
ques pour stocker, dplacer ou expdier des
cartes PC. LE SOUDAGE LARC risque de
provoquer des interfrences.
 Lnergie lectromagntique peut gner le
DES ORGANES MOBILES peuvent fonctionnement dappareils lectroniques
provoquer des blessures. comme des ordinateurs et des robots.
 Ne pas sapprocher des organes mobiles.  Veiller ce que tout lquipement de la zone de
soudage soit compatible lectromagntiquement.
 Ne pas sapprocher des points de coincement
 Pour rduire la possibilit dinterfrence, maintenir les cbles de
tels que des rouleaux de commande. soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
 Veiller souder une distance de 100 mtres de tout quipe-
LES FILS DE SOUDAGE peuvent ment lectronique sensible.
provoquer des blessures.  Veiller ce que ce poste de soudage soit pos et mis la terre
conformment ce mode demploi.
 Ne pas appuyer sur la gchette avant den
avoir reu linstruction.  En cas dinterfrences aprs avoir pris les mesures prcden-
tes, il incombe lutilisateur de prendre des mesures suppl-
 Ne pas diriger le pistolet vers soi, dautres mentaires telles que le dplacement du poste, lutilisation de
personnes ou toute pice mcanique en enga- cbles blinds, lutilisation de filtres de ligne ou la pose de protec-
geant le fil de soudage. teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements


 Les quipements de soudage et de coupage produisent des Pour les moteurs essence :
fumes et des gaz qui contiennent des produits chimiques dont  Les gaz dchappement des moteurs contiennent des produits
ltat de Californie reconnat quils provoquent des malformations chimiques dont ltat de Californie reconnat quils provoquent
congnitales et, dans certains cas, des cancers. (Code de sant et des cancers et des malformations congnitales ou autres pro-
de scurit de Californie, chapitre 25249.5 et suivants) blmes de procration.
 Les batteries, les bornes et autres accessoires contiennent du Pour les moteurs diesel :
plomb et des composs base de plomb, produits chimiques  Les gaz dchappement des moteurs diesel et certains de leurs
dont ltat de Californie reconnat quils provoquent des can- composants sont reconnus par ltat de Californie comme
cers et des malformations congnitales ou autres problmes de provoquant des cancers et des malformations congnitales ou au-
procration. Se laver les mains aprs manipulation. tres problmes de procration.
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2-5. Principales normes de scurit
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (tlphone :
de Global Engineering Documents (tlphone : 1-877-413-5184, site In- 800-463-6727 ou Toronto 416-747-4044, site Internet :
ternet : www.global.ihs.com). www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard AWS ANSI Standard Z87.1, de American National Standards Institute, 11 West
F4.1 de Global Engineering Documents (tlphone : 1-877-413-5184, site 42nd Street, New York, NY 10036-8002 (tlphone : 212-642-4900, site
Internet : www.global.ihs.com). Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org). Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (tlphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite OSHA, Occupational Safety and Health Standards for General Industry,
1004, Arlington, VA 22202-4102 (tlphone : 703-412-0900, site Internet Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
: www.cganet.com). Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux rgionauxle tlphone de la rgion 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF


Considrations sur le soudage et les effets de basse frquence et des 1. Maintenir les cbles ensemble en les tordant ou en les enveloppant.
champs magntiques et lectriques.
Le courant de soudage, pendant son passage dans les cbles de souda- 2. Disposer les cbles dun ct et distance de loprateur.
ge, causera des champs lectromagntiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les cbles autour de
certain souci propos de tels champs. Cependant, aprs avoir examin
plus de 500 tudes qui ont t faites pendant une priode de recherche votre corps.
de 17 ans, un comit spcial ruban bleu du National Research Council a
4. Garder le poste de soudage et les cbles le plus loin possible de
conclu : Laccumulation de preuves, suivant le jugement du comit, na
vous.
pas dmontr que lexposition aux champs magntiques et champs lec-
triques haute frquence reprsente un risque la sant humaine . 5. Connecter la pince sur la pice aussi prs que possible de la sou-
Toutefois, des tudes sont toujours en cours et les preuves continuent
dure.
tre examines. En attendant que les conclusions finales de la recherche
soient tablies, il vous serait souhaitable de rduire votre exposition aux En ce qui concerne les stimulateurs cardiaques
champs lectromagntiques pendant le soudage ou le coupage. Les porteurs de stimulateur cardiaque doivent consulter leur mdecin
Pour rduire les champs magntiques sur le poste de travail, appliquer avant de souder ou dapprocher des oprations de soudage. Si le mde-
les procdures suivantes : cin approuve, il est recommand de suivre les procdures prcdentes.

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SECTION 3 INSTALLATION
3-1. Specifications
A. 220-230/460-575 Volts Model*
Welding Input Rated Welding Maximum Amperes Input At Rated
Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
220 230 460 575
280 A @
31.2 VDC,
35.0 34.2 17.8 14.7 14.6 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.3 22.5 11.7 9.7 9.6 6.4
100 % (343 mm)
Stick Duty Cycle 7-1/2
W: 7 1/2 in 41 lb
77 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 10.1 6.6 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
32.7 32.0 n/a n/a 7.3 4.6
100 %
Duty Cycle
*Unit can be ordered with Dinse or Tweco weld output receptacles.

B. 208-230/400-460 Volts Model*


Welding Input Rated Welding Maximum Amperes Input At Rated
Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
208 230 400 460
280 A @
31.2 VDC,
36.0 34.0 19.8 17.5 14.0 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.5 22.8 13.5 12.7 10.2 6.9
100 % (343 mm)
Stick Duty Cycle W: 7
7-1/2
1/2 in 41 lb
67 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 9.9 6.5 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
35.0 32.9 n/a n/a 7.6 4.8
100 %
Duty Cycle
*Unit can be ordered with Dinse or Tweco weld output receptacles.

OM-217 655 Page 9

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C. 208-230/400-460 Volts VRD Model*

Welding Input Rated Welding Maximum Amperes Input At Rated


Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
208 230 400 460
280 A @
31.2 VDC,
36.0 34.0 19.8 17.5 14.0 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.5 22.8 13.5 12.7 10.2 6.9
100 % (343 mm)
Stick Duty Cycle 7-1/2
W: 7 1/2 in 41 lb
30 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 9.9 6.5 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
35.0 32.9 n/a n/a 7.6 4.8
100 %
Duty Cycle
*Unit can be ordered with Dinse or Tweco weld output receptacles.

3-2. 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, and
cooling fan runs. Wait fifteen
minutes for unit to cool. Reduce
amperage or duty cycle before
welding.
 Exceeding duty cycle can
damage unit and void
warranty.

221 587-A

200 A @ 50% Duty Cycle For Single Phase Operation 280 A @ 35% Duty Cycle For 3 Phase Operation

5 Minutes Welding 5 Minutes Resting 3-1/2 Minutes Welding 6-1/2 Minutes Resting

Overheating
0 A or V

15
OR
Minutes Reduce Duty Cycle

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3-3. Stick (SMAW) Volt-Ampere Curves CST 280 Model
xx10 Stick VA Curves Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
100 shown.

90

80

70

60
DC VOLTS

575V Primary
50

40
208V Primary
30

20
280A
STIFF
10
30A SOFT 30A STIFF 280A SOFT
0
0 50 100 150 200 250 300 350 400 450
DC AMPS

xx18 Stick VA Curve

100

90

80
575V Primary
70

60
DC VOLTS

50

40 208V Primary

30

20

10 30A 30A STIFF 280A


280A SOFT
SOFT STIFF
0
0 50 100 150 200 250 300 350 400
DC AMPS

Ref. 221 588-A

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3-4. TIG (GTAW) Volt-Ampere Curve CST 280 Model
Volt-ampere curves show minimum
TIG VA Curve and maximum voltage and
amperage output capabilities of
80 welding power source. Curves of
other settings fall between curves
70 shown.

60

50
DC VOLTS

40

30

20

10

0
0 50 100 150 200 250 300
DC AMPS

Ref. 221 588-A

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3-5. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model
Volt-ampere curves show minimum
and maximum voltage and
xx10 Stick VA Curves amperage output capabilities of
welding power source. Curves of
other settings fall between curves
90 shown.

80

70

60
DC VOLTS

50

40

30
280A STIFF
20

10
30A SOFT 30A STIFF 280A SOFT
0
0 50 100 150 200 250 300 350 400
DC AMPS

xx18 Stick VA Curve

90

80

70

60
DC VOLTS

50

40

30

20

10
30A 30A STIFF 280A 280A
SOFT SOFT STIFF
0
0 50 100 150 200 250 300 350 400
DC AMPS

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3-6. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model
Volt-ampere curves show minimum
TIG VA Curve and maximum voltage and
amperage output capabilities of
35
welding power source. Curves of
other settings fall between curves
shown.
30

25

20
DC VOLTS

15

10

0
0 50 100 150 200 250 300
DC AMPS

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3-7. Selecting A Location
1 Line Disconnect Device
Locate unit near correct input
power supply.
Dimensions And Weight  Special installation may be
40 lb (18.2 kg) - with power cord required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
18 in
Section 20.
(457 mm)

13-1/2 in
(343 mm)

7-1/2 in
(191 mm)

Location And Airflow

18 in
(460 mm)

18 in
(460 mm)

803 942-A

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3-8. Weld Output Terminals And Selecting Cable Sizes*

 ARC WELDING can cause Electromagnetic Interference.


To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
 Turn off power before 10
60 100%
connecting to weld out- Welding 60%
Duty 10 100% Duty Cycle
put terminals. Amperes*** Duty
Cycle
 Do not use worn, dam- Cycle
aged, undersized, or
poorly spliced cables.

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0


250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0


300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
+
Output Receptacles 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***Select weld cable size for pulsing application at peak amperage value. S-0007-F803 080

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3-9. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections
1 Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4 2 Negative () Weld Output
5
Terminal
6 Connect TIG torch to negative weld
output terminal.

3 3 Gas Cylinder
4 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5 Regulator/Flowmeter
6 Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas hose to
regulator/flowmeter.
1 7 Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.

2
7

Tools Needed:

11/16 in, 1-1/8 in, (21 mm)

803 943-A

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3-10. Stick DCEP (Direct Current Electrode Positive) Connections
1 Negative () Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2 Positive (+) Weld Output
Terminal
Connect electrode holder to
positive weld output terminal.

803 944-A

3-11. Electrical Service Guide

 CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding
power source requires a CONTINUOUS supply of 50/60 Hz power at +10% of rated input voltage. Do
not use a generator with automatic idle device (that idles engine when no load is sensed) to supply
generator input power to this welding power source.

NOTE Actual input voltage cannot exceed 10% of indicated required input voltage. If
actual input voltage is outside of this range, inadvertent shutdown may occur.

50/60 Hz Single-
50/60 Hz Three-Phase,
Phase, 50% Duty
35% Duty Cycle
Cycle

Input Voltage 208 220 230 208 220 230 400 460 575

Input Amperes At Rated Output 43.9 43.9 43.0 36.0 35.0 34.2 19.8 17.8 14.7

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay 2 50 50 50 45 45 45 25 20 15

Normal Operating 3 70 70 70 60 60 50 30 25 20

Min Input Conductor Size In AWG4 8 8 8 10 10 10 14 14 14

117 129 141 101 113 123 149 196 306


Max Recommended Input Conductor Length In Feet (Meters)
(36) (39) (43) (31) (34) (38) (45) (60) (93)

Min Grounding Conductor Size In AWG4 8 8 8 10 10 10 14 14 14

Reference: 2005 National Electrical Code (NEC) (including article 630)


1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 Time-Delay fuses are UL class RK5 .
3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
 Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
OM-217 655 Page 18

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3-12. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage
 Turn Off welding power
source, and disconnect
input power before
proceeding.
208-230/400-460 Volts Model Check input voltage available at
1 site.
1 Switch Cover
2 Voltage Selection Switch
The input voltage that the power
source is linked for is labeled next to
the switch.
208230 400460
VAC VAC Check voltage selected on unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
2
 Do not switch under load.
To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position


at 905 straight up.
Be sure that switch is turned
completely to its detent position.

220-230/460-575 Volts Model


1

220230 460575
VAC VAC

Tools Needed:

Ref. 803 945-A / Ref. 803 946-A

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3-13. Selecting 400 - 575 Volts AC Three Phase Input Voltage
 Turn Off welding power
source, and disconnect
input power before
proceeding.
208-230/400-460 Volts Model
1 Check input voltage available at
site.
1 Switch Cover
2 Voltage Selection Switch
The input voltage that the power
source is linked for is labeled next to
208230 400460 the switch.
VAC VAC
Check voltage selected on unit.
Changing selection is only
necessary if selected value does
2 not match available input voltage.
 Do not switch under load.
To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position


at 905 straight up.
Be sure that switch is turned
completely to its detent position.

220-230/460-575 Volts Model


1

220230 460575
VAC VAC

Tools Needed:

Ref. 803 945-A / Ref. 803 946-A

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3-14. Connecting 1-Phase Input Power
 Installation must meet all National
and Local Codes have only quali-
fied persons make this installation.
 Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
 Always connect green or green/
1 yellow conductor to supply
grounding terminal first, and never
to a line terminal.
See rating label on unit and check input
8 =GND/PE Earth Ground voltage available at site.
1 Black And White Input Conductor
(L1 And L2)
10
2 Red Input Conductor
3 Green Or Green/Yellow Grounding
Conductor
7 4 Insulation Sleeving
5 Electrical Tape
9 Insulate and isolate red conductor as
shown.
6 Input Power Cord.
L1 7 Disconnect Device (switch shown in
1
L2 the OFF position)
3 8 Disconnect Device Grounding
Terminal
1 9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
6 conductor to disconnect device grounding
terminal first.
2 Connect input conductors L1 and L2 to
disconnect device line terminals.
3
10 Over-Current Protection
Select type and size of over-current
6 protection using Section 3-11 (fused dis-
connect switch shown).
4
5 Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

803 766-A / 803 942-A

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3-15. Connecting 3-Phase Input Power
 Installation must meet all National
and Local Codes have only quali-
fied persons make this installation.

3  Disconnect and lockout/tagout in-


put power before connecting input
conductors from unit.
 Always connect green or green/
= GND/PE Earth Ground yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4 See rating label on unit and check input
voltage available at site.
1 Input Power Cord.
2 Disconnect Device (switch shown in
7 the OFF position)
3 Green Or Green/Yellow Grounding
Conductor
4 Disconnect Device Grounding
Terminal
5 Input Conductors (L1, L2 And L3)
2
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.
L1 7 Over-Current Protection

3 Select type and size of over-current


L2 5
protection using Section 3-11 (fused dis-
connect switch shown).
6 L3
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

803 766-A / 803 942-A

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SECTION 4 OPERATION
4-1. Controls

2 5 3 4

NOTE: Green on nameplate indicates a TIG 2 Output Indicator Light 4 Amperage Control
function, Gray indicates a Stick function. When unit is first energized this indicator See Section 4-5.
1 Power Switch light flashes several times and then 5 High Temperature Shutdown Light
illuminates continuously. When unit is shut When unit is first energized this indicator
Use switch to turn unit and indicator light down, the indicator light flashes several
On/Off. light illuminates for approximately 1 second
times and the cooling fan will run briefly, to provide visual confirmation that the light
then both will turn off completely. is functioning properly (see Section 3-2).
3 Process Control 6 Remote 14 Receptacle
See Section 4-2.

Ref. 217 192-A / 803 942-A

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4-2. Process Select Control
1 Process Select Control
Rotate knob to select desired
process.
Lift-Arc TIG - Normal
1 open-circuit voltage is not present
between the electrode and
workpiece. A solid-state contactor
does not energize until after the
electrode touches the workpiece,
preventing overheating, sticking, or
contaminating the electrode (see
Section 4-4). Make connections
according to Section 3-9.
Stick E XX18 Soft - This setting
provides a lower dig/arc force
setting for smooth weld perfor-
mance. A stable weld puddle with
little arc snap gives excellent weld
bead appearance with minimal
spatter. Make connections
according to Section 3-10.
Stick E XX18 Stiff - This setting
provides a higher dig/arc force that
gives a slightly more fluid weld
puddle, more arc snap, and
reduces the potential for electrode
sticking at shorter arc lengths.
Make connections according to
Section 3-10.
Stick E XX10 Soft - This setting
provides lower dig/arc force for
open root vertical up joints or joints
that do not require additional
current for fit up inconsistencies.
RECOMMENDED PROCESS Make connections according to
SELECTIONS VS ELECTRODE TYPE Section 3-10.
Stick E XX10 Stiff - This setting
ELECTRODE SUGGESTED PROCESS provides a higher dig/arc force for
TYPE SETTING open root vertical down joints
where additional current is needed
EXXX1 EXX10 to compensate for tight joint fit up
EXXX2 EXX10 without the need to increase overall
welding current. Make connections
according to Section 3-10.
EXXX3 EXX18
EXXX4 EXX18
EXXX5 EXX18
EXXX6 EXX18
EXXX7 EXX18
EXXX8 EXX18
STAINLESS EXX18

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4-3. Stick Start Procedure Scratch Start Technique
With Stick selected, start arc as
follows:
1 Electrode
2 Workpiece
3 Arc
1 Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
2 VRD Model Only: Normal
open-circuit voltage is not present
before electrode touches workpiece;
3 only a low sensing voltage is present
between electrode and workpiece.
This allows electrode to touch
workpiece without overheating,
sticking, or getting contaminated.

4-4. Lift-Arc Start Procedure


Lift-Arc Start
With Lift-Arc selected, start arc
as follows:
1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
Lift-Arc Start Method workpiece for 1-2 seconds, and
1 2 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
12 electrode and workpiece. The
Touch Seconds solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.

Do NOT Strike Like A Match!

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4-5. Amperage Control
1 AMP ADJUST (Amperage
Control)
1
Rotate knob clockwise to increase
amperage (5-280 amps).

4-6. Remote 14 Receptacle Information


This unit automatically senses when a remote control is connected to the remote 14 receptacle. After connecting a
remote control, the unit will automatically adjust output control to a primary/secondary configuration. In this
configuration, the AMP ADJUST control on the unit becomes the primary and sets the maximum amperage output of
the unit. The remote control becomes the secondary and provides an amperage range adjustment of 0 to 100% based
on the AMP ADJUST control setting.

Socket* Socket Information


A J
K I
B
C L N H A 15 volts dc (not functional).
D M G 15 VOLTS DC
E F B Contact closure to A completes 15 volts dc
contactor control circuit (not functional).

C Output to remote control; 0 to +10 volts dc.

REMOTE D Remote control circuit common.


OUTPUT
CONTROL
E 0 to +10 volts dc input command signal from
remote control.

K Chassis common.
803 942-A GND

*The remaining sockets are not used.

4-7. Fan-On-Demand
This unit is equipped with Fan-On-Demand. The fan operates only when necessary to cool internal components. At
power down, the fan will operate for a short period of time while the output indicator light is flashing.

4-8. Rack Mounting


This unit is capable of being rack mounted see rack Owners Manual, OM-221 611.

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SECTION 5 MAINTENANCE AND TROUBLESHOOTING

5-1. Routine Maintenance


 Disconnect power before maintaining.

 Maintain more often during severe conditions.

3 Months

Replace Clean and tighten Replace Damaged


unreadable weld terminals. Gas Hose
labels.

3 Months

Repair Or Replace
Cracked Cables
And Cords

6 Months
 Do not remove case when
blowing out inside of unit
(see Section 5-2) .
Blow out inside. During
heavy service clean
monthly.

5-2. Blowing Out Inside Of Unit


 Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.

803 942-A

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5-3. Troubleshooting
1 Output LED (Blue)
2 High Temperature LED
(Yellow)

803 942-A

Repeated LED Flashes Indicate


Status
Red (LED3
Blue Yellow Trouble Possible Causes Remedy
on PC3)
Place line disconnect switch in
Line Disconnect open. on position (see Section 3-14 or
3-15).
Check and replace line fuses, if
No weld output; necessary, or reset circuit
None None None unit completely Blown fuses.
breaker (see Section 3-14 or
inoperative. 3-15).
Check for proper input connec-
Improper input connections.
tions (see Section 3-12 or 3-13).
Fuse F1 on PC2 blown. Check and replace F1.
Line voltage too high or
Line voltage must be 10%.
too low.

Flashes Con- Check line voltage and link ac-


0 7 No weld output. Not ready. Unit is linked incorrectly.
tinuously cordingly.
Check DC buss caps and PC2,
Buss voltage imbalance.
and replace if necessary.
Check CT1 and wiring for an
No primary lfb.
open condition.
Check for shorts or opens in
Failed output diode(s).
wiring.

6 0 1 No weld output. Current latch. Replace boost inductor if neces-


Failed boost inductor.
sary.
Failed LEM. Replace LEM if necessary.
Open connection be- Inspect all wiring and connec-
tween LEM and PC1. tions.
Check for a shorted relay or wir-
Shorted boost relay.
ing.
Boost relay does not
deenergize after termina- Check PC1.
4 0 8 No weld output. Voltage latch. tion of weld.
Voltage in excess of
100V from another Check for external voltage
source applied across sources.
output studs.

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Repeated LED Flashes Indicate
Status
Red (LED3
Blue Yellow Trouble Possible Causes Remedy
on PC3)
Vfb leads not connected Check Vfb leads for proper wir-
or reversed. ing and connection.
Short circuit across out-
5 0 11 No weld output. Voltage loss. Check for shorts.
put studs.
Check PC2 and replace if nec-
Failed IGBT on PC2.
essary.

Output fold- Single phase rating ex- Reduce output to 200 amperes
Reduced weld back due to ceeded. or less.
2 0 6
output. excessive in- High output VA coupled Check line voltage and weld
put current. with a low 230V line. settings.
Remove trigger, wait approxi-
3 0 10 Remote trigger has been left on.
mately 5 seconds, and restart.
Primary (IGBT) thermis- Allow unit to cool down.
3 No weld output.
On Unit over
over- tor over temperature. Retorque PM1, PM2, and PM3
0
continuously heated. Secondary thermistor mounting hardware to 25 in lbs
5 (2.8 Nm).
over temperature.
Shorted primary (IGBT) Check IGBT thermistors for
0
thermistor. shorts.
Open primary (IGBT) Check IGBT thermistors and
2
thermistor. associated wiring for opens.
Flashes Thermistor Check thermistor on output
0 No weld output. Open secondary thermis-
continuously 4 failure. heatsink and associated wiring
tor.
for opens.
Check thermistor on ouput heat-
Shorted secondary
9 sink and associated wiring for
thermistor.
shorts.
Check for and remove anything
Blocked fan.
Fan not operat
operat- blocking fan movement.
N/A N/A N/A
ing. Have factory authorized service
Fan failure.
agent check fan motor.
Use proper size and type of
Weld cables too small or defective.
Erratic or im
im- weld cables (see Section 3-8).
N/A N/A N/A proper weld Clean and tighten all weld cable
output. Dirty or loose connections. connections (see Section 3-9 or
3-10).
Use proper size tungsten (see
Improper tungsten.
Section 7-1).
Use properly prepared tungsten
N/A N/A N/A Wandering arc. Worn or defective tungsten.
(see Section 7-3).
Reduce gas flow rate (see Sec-
Gas flow too high.
tion 3-9).
Gas is blown away from weld zone. Shield weld zone from drafts.
Tungsten elec- Allow adequate postflow time to
trode oxidizing Inadequate postflow time. shield tungsten while it is cool-
and not remain- ing after welding stops.
N/A N/A N/A ing bright after
conclusion of Check and tighten all gas fit-
Loose or leaking gas fittings.
weld. tings (see Section 3-9).
Water in torch. Refer to torch manual.

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SECTION 6 ELECTRICAL DIAGRAMS

Figure 6-1. Circuit Diagram

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217 589-B

OM-217 655 Page 31

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SECTION 7 SELECTING AND PREPARING TUNGSTEN
ELECTRODE
gtaw 7/97

NOTE For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.

7-1. Selecting Tungsten Electrode

Amperage Range - Gas Type - Polarity


Electrode Diameter DC Argon Electrode DC Argon Electrode AC Argon Using AC Argon Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
2% Thorium Alloyed
Tungsten (Red Band)
.010 Up to 25 * Up to 20 Up to 15
.020 15-40 * 15-35 5-20
.040 25-85 * 20-80 20-60
1/16 50-160 10-20 50-150 60-120
3/32 135-235 15-30 130-250 100-180
1/8 250-400 25-40 225-360 160-250
5/32 400-500 40-55 300-450 200-320
3/16 500-750 55-80 400-500 290-390
1/4 750-1000 80-125 600-800 340-525

Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.

The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.

7-2. Safety Information About Tungsten


 Grinding the tungsten elec-
trode produces dust and fly-
ing sparks which can cause
injury and start fires. Use lo-
1 cal exhaust (forced ventila-
tion) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-lev-
2 el radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1 Tungsten Electrode With
Balled End
2 Pointed Tungsten Electrode

Ref. S-0161

OM-217 655 Page 32

Downloaded from www.Manualslib.com manuals search engine


7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1 Tungsten Electrode
1 2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.

2-1/2 Times
Electrode Diameter

1 Stable Arc
2 Flat
1
Diameter of this flat determines
amperage capacity.
2
3 Grinding Wheel
3 Grinding wheel should be dedi-
cated to grinding tungsten only.
4 Straight Ground

4
Ideal Tungsten Preparation Stable Arc

1 Arc Wander
2 Point
1 3 Grinding Wheel
Grinding wheel should be dedi-
2 cated to grinding tungsten only.
4 Radial Ground

Wrong Tungsten Preparation Wandering Arc

Ref. S-0161 / Ref. S-0162

OM-217 655 Page 33

Downloaded from www.Manualslib.com manuals search engine


SECTION 8 PARTS LIST

 Hardware is common and


not available unless listed.

10 8

24
18
17

15 15

6 11

23

22
13
13
12 20

30 7 26

21
16
9
14
3

19 2

16

25

803 947-B

Figure 8-1. Main Assembly


OM-217 655 Page 34

Downloaded from www.Manualslib.com manuals search engine


Quantity
Model
Item Part
No. No. Description 907 251 907 244

Figure 8-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 221585 .. PANEL,FRONT W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1


. . . 2 . . . . . . . . . . . . . . 221586 .. PANEL,REAR W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 3 . . . . . . . . . . . . . . 212809 .. MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 206037 .. MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 206090 .. HEAT SINK ASSEMBLY,OUTPUT DIODE . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 5 . . . . . . . . . . . . . . 206039 .. BASE ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 6 . . . . . . . . . . . . . . 206093 .. BRACKET,MTG CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 7 . . . . . . . . . . . . . . 206038 .. HEAT SINK ASSEMBLY,INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 8 . . . . . . . . . . . . . +217216 .. WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . 203990 .. LABEL,WARNING GENERAL PRECAUTIONARY STATIC . . . . 1 . . . . 1
. . . 9 . . . . . . . . . . . . . +207437 .. CABLE,POWER 6 FT 10GA 4C BLK/RED/WHT/GRNYEL . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . 182826 .. LABEL,WARNING ELECTRIC SHOCK POWER CORD . . . . . . . 1 . . . . 1
. . . 10 . . . . . . . . . . . . . . 206108 .. HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 11 . . . . . . . . . . . . . . 206289 .. LINK,CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 1
. . . 12 . . PLG3 . . . . . 206247 .. PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 13 . . PLG4 . . . . . 206254 .. PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 14 . . . . . . . . . . . . . . 196231 .. XFMR,CURRENT SENSING 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 15 . . . . . . . . . . . . . . 206270 .. INSULATOR,SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 16 . . PLG5 . . . . . 206276 .. CABLE,LEM W/PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 17 . . C1,C2 . . . . +203912 .. CAPACITOR,ELCTLT 2400 UF 500 VDC CAN 2.5 DIA . . . . . . . . 2 . . . . 2
. . . . . . . . . . . . . . . . . . . . 126026 .. LABEL,WARNING ELECTRIC SHOCK CAN KILL SIGNIFICANT 2 . . . . 2
. . . 18 . . . . . . . . . . . . . . 205908 .. CLAMP,CAPACITOR 2.500 DIA HORIZONTAL MTG NYLON . . 1 . . . . 1
. . . 19 . . . . . . . . . . . . . . 189777 .. RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 20 . . . PC2 . . . . . . 222447 .. KIT,CIRCUIT CARD ASSY INTERCONNECT . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 21 . . . PC1 . . . . . . 221472 .. CIRCUIT CARD ASSY,POWER CONTROL . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 22 . . . . . . . . . . . . . . 217587 .. FUSE,CRTG 2. AMP 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 23 . . . . . . . . . . . . . . 176879 .. SCREW,M 5 .8X 12 HEX HDPHL . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 6
. . . 24 . . . . . . . . . . . . . . 207113 .. WASHER,CONE .205IDX0.394ODX.015T STL . . . . . . . . . . . . . . . 2 . . . . 2
. . . 25 . . . . . . . . . . . . . . 200550 .. SCREW,M101.5X 20 HEX HDPLN 8.8 PLD SEMS . . . . . . . . . 2 . . . . 2
. . . 26 . . . . . . . . . . . . . . 217249 .. SWITCH ASSY,RELINKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-217 655 Page 35

Downloaded from www.Manualslib.com manuals search engine


 Hardware is common and 8
not available unless listed.
19 20

4 24
7
2
18

14
23

9
13
12
25
6 22 15
5 3
7

17
11
21 16

10 803 158-A

Figure 8-2. Panel, Front w/Components


Quantity
Model
Item Dia. Part 907251 907244 907251012
No. Mkgs. No. Description

Figure 8-2. Panel, Front w/Components

... 1 .............. 194242 .. PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1


... 2 .............. 205759 .. PANEL,FRONT UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 3 .............. 195647 .. PANEL,FRONT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 4 . . . . S1 . . . . . . 207165 .. SWITCH,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 5 .............. 174991 .. KNOB,POINTER 1.250 DIA X .250 ID
W/SPRING CLIP.21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
. . . 6 . . . . . . . . . . . . . . 174992 . . KNOB,POINTER .840 DIA X .250 ID
W/SPRING CLIP.21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 7 . . RC14 . . . . . 207144 .. RECEPTACLE W/LEADS&PLUG,(14 PIN) . . . . . . . . . . . . 1 . . . . 1 .... 1
... 8 .............. 193115 .. STANDOFF SUPPORT,PC CARD .156 DIA/.375 LG . . 3 . . . . 3 .... 3
... 9 .............. 178548 .. TERMINAL,CONNECTOR FRICTION . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 10 .............. 209473 .. RECEPTACLE,TWIST LOCK TWECO(FEMALE) . . . . . . 2
... 10 .............. 202553 .. RECEPTACLE,TWIST LOCK DINSE(FEMALE) . . . . . . . . . . . . . . 2 .... 2
... 11 .............. 185712 .. INSULATOR,BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 12 .............. 185713 .. INSULATOR,BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 13 .............. 185714 .. WASHER,TOOTH 22MMID X 31.5MMOD
1.3101MMT INTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 14 .............. 185717 .. NUT,M201.5 1.06HEX .19H BRS LOCKING . . . . . . . . . 2 . . . . 2 .... 2
... 15 .............. 185718 .. ORING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 16 .............. 186228 .. ORING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 17 .............. 207253 .. BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 18 .............. 217192 .. NAMEPLATE,MILLER CST 280 . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
OM-217 655 Page 36

Downloaded from www.Manualslib.com manuals search engine


Quantity
Model
Item Dia. Part 907251 907244 907251012
No. Mkgs. No. Description

Figure 8-2. Panel, Front w/Components (Continued)

... 19 . . . PC4 . . . . . . 205764 .. CIRCUIT CARD ASSY,OPERATOR INTERFACE . . . . . . 1 . . . . 1 . . . . 1


... 20 . . . PC3 . . . . . . 221467 .. CIRCUIT CARD ASSY,PROCESS CONTROL . . . . . . . . 1 . . . . 1
... 20 . . . PC3 . . . . . . 221619 .. CIRCUIT CARD ASSY,PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . 1
... 21 .............. 170391 .. CONNECTOR, CIRC MS PROTECTIVE CAP . . . . . . . . . 1 . . . . 1 . . . . 1
... 22 .............. 178355 .. NUT, 37532 .54HEX .25H NYL FLANGE .62D . . . . . . . 2 . . . . 2 . . . . 2
... 23 .............. 209554 .. SCREW, KA35X 8 PAN HDPHL . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
... 24 .............. 097132 .. STANDOFF,NO 632 X .375 LG .250 HEX BRS M&F . 1 . . . . 1 . . . . 1
... 25 .............. 230485 .. KNOB,SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
 Hardware is common and
not available unless listed.

2
3
803 948-A

Figure 8-3. Panel, Rear w/Components


Item Part
No. No. Description Quantity

Figure 8-3. Panel, Rear w/Components

... 1 . . . . . . . . . . 194242 .. PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 . . . . . . . . . . 206053 .. PANEL,REAR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . 210128 .. BRACKET,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . 145217 .. SCREW,K40X 12 PAN HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . 207253 .. BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . 201155 .. BUSHING,STRAIN RELIEF .450/.709 ID X1.068 MTG HOLE . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-217 655 Page 37

Downloaded from www.Manualslib.com manuals search engine


 Hardware is common and 10
not available unless listed.

8
11

13

8
1
12

5
2
4 804 206-A

Figure 8-4. Magnetics Subassembly

Quantity
Item Diagram Part Model
No. Marking No. Description 907 251 907 244

Figure 8-4. Magnetics Subassembly

... 1 .............. 206063 .. PANEL,PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 . . . . T1 . . . . . . 212812 .. XFMR,HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . . T1 . . . . . . 206065 .. XFMR,HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . FM . . . . . . 196887 .. FAN,MUFFIN 24VDC 3000 RPM 130 CFM 4.125 MTG HOLES 1 . . . . 1
... 4 . . . . Z1 . . . . . . 206064 .. INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 5 . . . CR1 . . . . . . 206258 .. RELAY,ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . 1 . . . . 1
... 6 . . . . R3 . . . . . . 206281 .. RESISTOR,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 7 . . . . C3 . . . . . . 196143 .. CAPACITOR,POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . 1 . . . . 1
... 8 .............. 057357 .. BUSHING,SNAPIN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . 3 . . . . 3
... 9 . . . . L3 . . . . . . 225189 .. COIL,INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 10 .............. 198634 .. BRACKET,FRONT HEATSINK MTG . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 11 .............. 083147 .. GROMMET,SCR NO 8/10 PANEL HOLE .312 SQ .500 HIGH . . 1 . . . . 1
... 12 .............. 136343 .. SCREW,K50X 20 PAN HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
... 13 .............. 170647 .. BUSHING,SNAPIN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . 1 . . . . 1

To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-217 655 Page 38

Downloaded from www.Manualslib.com manuals search engine


 Hardware is common and
not available unless listed.

3 803 949-B

Figure 8-5. Relinking Switch And Door Assembly

Quantity
Model
Item Dia. Part
No. Mkgs. No. Description 907 251 907 244

Figure 8-5. Relinking Switch And Door Assembly

. . . 1 . . . . . . . . . . . . . +217252 .. DOOR ASSY,RELINKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1


. . . . . . . . . . . . . . . . . . . . 221460 .. LABEL,220230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221461 .. LABEL,460575 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221458 .. LABEL,208230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221459 .. LABEL,400460 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221462 .. LABEL,,CAUTION OPERATING LINK SWITCH ETC . . . . . . . . . 1 . . . . 1
. . . 2 . . . . . . . . . . . . . . 217647 .. SWITCH,ROTARY 3 POSN 4P 32A 600V 180 DEG (SPL) . . . . . 1 . . . . 1
. . . 3 . . . . . . . . . . . . . . 209554 .. SCREW,KA35X 8 PAN HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 4 . . . . . . . . . . . . . . 221573 .. NUT,SPEED SNAPIN 1/4 TURN . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 5 . . . . . . . . . . . . . . 221575 .. RETAINER,NYLON PUSHON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 6 . . . . . . . . . . . . . . 221574 .. SCREW,1/4 TURN OVAL HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-217 655 Page 39

Downloaded from www.Manualslib.com manuals search engine


 Hardware is common and 10
not available unless listed.
11
12
12

7
6
2

9
3
8

803 159-D

Figure 8-6. Heat Sink Assembly, Output Diode

Item Diagram Part


No. marking No. Description Quantity

Figure 8-6. Heat Sink Assembly, Output Diode

... 1 . . . . . . . . . . 205916 .. HEAT SINK,DIODE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 . . D1,D2 . 223422 .. KIT,DIODE ULTRAFAST RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . SR1 . . 201530 .. KIT,DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . HD1 . . 191941 .. TRANSDUCER,CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . R2,C6 . 196510 .. RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . R1,C5 . 207384 .. RESISTOR/CAPACITOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . RT1 . . 209223 .. THERMISTOR,NTC 30K OHM @ 25 DEG C 18IN LEAD . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . 049611 .. TUBING,COP .540 OD X .123 WALL X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . 207932 .. INSULATOR,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . 108942 .. SCREW,25020X1.25 HEXWHD.61D GR5 PLD . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . 602 062 .. SCREW,00440X .37 PAN HDPHL STL PLD CONE SEMS . . . . . . . . . . . . . 5
... 12 . . . . . . . . . . 207451 .. SCREW,00832X .50 PAN HDPHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . . 7

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

OM-217 655 Page 40

Downloaded from www.Manualslib.com manuals search engine


 Hardware is common and
not available unless listed.

1
6
7
8

2
5

803 160

Figure 8-7. Base Assembly

Item Diagram Part


No. marking No. Description Quantity

Figure 8-7. Base Assembly

... 1 .......... 206089 .. BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


... 2 .......... 019663 .. MOUNT,NPRN 15/16ODX3/8REC 3/16X3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 3 . . C7,C8 . 186543 .. CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .......... 133528 .. RIVET,AL .125 DIA X .188.250 GRIP BLK BLIND DOME . . . . . . . . . . . . . . . 4
... 5 .......... 195666 .. SCREW,01032X .62 HEXWHD.40D STL PLD SLFFMG TAPRW . . . . . . . . 2
... 6 .......... 601862 .. NUT, 01032 .38HEX .13H STL PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .......... 602203 .. WASHER,LOCK .193IDX0.334ODX.047T STL PLD SPLIT #10 . . . . . . . . . . . 2
... 8 .......... 602238 .. WASHER,FLAT .203IDX0.500ODX.048T STL PLD ANSI#10 . . . . . . . . . . . . . 2

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

OM-217 655 Page 41

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 Hardware is common and
not available unless listed.

803 162-B

Figure 8-8. Heat Sink Assembly, Input

Item Diagram Part


No. marking No. Description Quantity

Figure 8-8. Heat Sink Assembly, Input

. . . 1 . . . . . . . . . . 205915 . . HEAT SINK,IGBT/INPUT RECTIFIER MODULE . . . . . . . . . . . . . . . . . . . . . . . . 1


. . . 2 . . . . . . . . . . 206091 . . BRACKET,HEATSINK REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . TE1 . . 206328 . . BLOCK,TERM 70 AMP 3 POLE SCREW TERM 414 WIRE . . . . . . . . . . . . . 1

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

OM-217 655 Page 42

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Effective January 1, 2007
(Equipment with a serial number preface of LH or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Replacement Parts (No labor)
Within the warranty periods listed below, Miller will repair or * Spoolmate Spoolguns
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which Millers True Blue Limited Warranty shall not apply to:
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings, relays
reliable response you Miller shall honor warranty claims on warranted equipment listed or parts that fail due to normal wear. (Exception:
need. Most replacement below in the event of such a failure within the warranty time brushes, slip rings, and relays are covered on Bobcat,
parts can be in your periods. All warranty time periods start on the delivery date of the Trailblazer, and Legend models.)
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed 2. Items furnished by Miller, but manufactured by others, such
one year after the equipment is shipped to a North American as engines or trade accessories. These items are covered
Support distributor or eighteen months after the equipment is shipped to by the manufacturers warranty, if any.
Need fast answers to the an International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
1. 5 Years Parts 3 Years Labor Miller, or equipment that has been improperly installed,
Contact your distributor.
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
distributor and Miller is 2. 3 Years Parts and Labor
necessary maintenance, or equipment which has been
there to help you, every * Transformer/Rectifier Power Sources used for operation outside of the specifications for the
step of the way. * Plasma Arc Cutting Power Sources equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Millers option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customers risk and expense. Millers option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Field Options BY MILLER.
(NOTE: Field options are covered under True Blue Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
* Bernard-Branded Mig Guns (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies
additional warranties or remedies other than as stated herein,
4. 6 Months Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days Parts provides specific legal rights, and other rights may be available,
* MIG Guns/TIG Torches and Subarc (SAW) Guns but may vary from province to province.
miller_warr 200701

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Owners Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.


Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International HeadquartersUSA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com

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 manufacturers
Transportation Department.

PRINTED IN USA 2007 Miller Electric Mfg. Co. 200701


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