OM-217 769L

200711

Processes
Multiprocess Welding

Description

Arc Welding Power Source

XMT 400
R

(400 Volt Model)

File: MULTIPROCESS
Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you 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 will help you protect yourself against potential hazards on the worksite. Weve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, 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.
Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business.

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

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TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utiliss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . . 2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Manufacturers Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Manufacturers Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Lift-Arc TIG Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 4 4 4 5 5 5 7 8 9 9 11 11 13 13 14 14 14 15 16 16 17 18 18 19 20 20 21 22 23 24 24 24 25 26 27 28

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

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Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

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

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first double-check connections. D Keep cords dry, free of oil and grease, and protected from hot metal and sparks. D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly with a separate cable. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owners Manual and national, state, and local codes.

SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power.
D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed. D Allow cooling period before working on gun or torch. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. OM-217 769 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. D Use only correct fuses or circuit breakers. Do not oversize or bypass them. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

MAGNETIC FIELDS can affect Implanted Medical Devices.

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

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. OM-217 769 Page 2

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

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

FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring be sure power supply system is properly sized, rated, and protected to handle this unit.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. D Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary. D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

READ INSTRUCTIONS.
D Read Owners Manual before using or servicing unit. D Use only genuine replacement parts from the manufacturer.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. D Sparks can cause fires keep flammables away.

D D D D

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. 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.

MOVING PARTS can cause injury.

D Keep away from moving parts. D Keep away from pinch points such as drive rolls.

D D D D

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

OM-217 769 Page 3

1-4. California Proposition 65 Warnings

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

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 100368002 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 Regional Officesphone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-6. EMF Information

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

OM-217 769 Page 4

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

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Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si on lvite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrs par les symboles joints ou sont expliqus dans le texte. Indique une situation dangereuse qui si on lvite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrs par les symboles joints ou sont expliqus dans le texte. NOTE Indique des dclarations pas en relation avec des blessures personnelles.

. Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y affrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce manuel pour attirer lattention et identifier les dangers possibles. En prsence de lun de ces symboles, prendre garde et suivre les instructions affrentes pour viter tout risque. Les instructions en matire de scurit indiques ci-dessous ne constituent quun sommaire des instructions de scurit plus compltes fournies dans les normes de scurit numres dans la Section 2-5. Lire et observer toutes les normes de scurit. Seul un personnel qualifi est autoris installer, faire fonctionner, entretenir et rparer cet appareil. Pendant le fonctionnement, maintenir distance toutes les personnes, notamment les enfants de lappareil. ( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations, lutilisation dun poste souder DC fil tension constante est recommande. En outre, ne pas travailler seul ! Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de loprateur et les normes nationales, provinciales et locales. Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. En effectuant les raccordements dentre, fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions. Les cbles doivent tre exempts dhumidit, dhuile et de graisse; protgezles contre les tincelles et les pices mtalliques chaudes.

D D

UNE DCHARGE LECTRIQUE peut entraner la mort.

Le contact dorganes lectriques sous tension peut provoquer des accidents mortels ou des brlures graves. Le circuit de llectrode et de la pice est sous tension lorsque le courant est dlivr la sortie. Le circuit dalimentation et les circuits internes de la machine sont galement sous tension lorsque lalimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc de commande du rouleau et toutes les parties mtalliques en contact avec le fil sont sous tension lectrique. Un quipement install ou mis la terre de manire incorrecte ou impropre constitue un danger. D Ne pas toucher aux pices lectriques sous tension. D Porter des gants isolants et des vtements de protection secs et sans trous. D Sisoler de la pice couper et du sol en utilisant des housses ou des tapis assez grands afin dviter tout contact physique avec la pice couper ou le sol. D Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. D Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. D Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. D Dautres consignes de scurit sont ncessaires dans les conditions suivantes : risques lectriques dans un environnement humide ou si lon porte des vtements mouills ; sur des structures mtalliques telles que sols, grilles ou chafaudages ; en position coince comme assise, genoux ou couche ; ou sil y a un risque lev de contact invitable ou accidentel avec la pice souder ou le sol. Dans ces conditions, utiliser les quipements suivants, dans lordre indiqu : 1) un poste souder DC tension constante

D D

D Vrifier frquemment le cordon dalimentation afin de sassurer quil nest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nu peut entraner la mort. D Lquipement doit tre hors tension lorsquil nest pas utilis. D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. D Ne pas enrouler les cbles autour du corps. D Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct. D Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine. D Ne pas toucher des porte lectrodes connects deux machines en mme temps cause de la prsence dune tension vide double. D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-lechamp les pices endommages. Entretenir lappareil conformment ce manuel. D Porter un harnais de scurit si lon doit travailler au-dessus du sol. D Sassurer que tous les panneaux et couvercles sont correctement en place. D Fixer le cble de retour de faon obtenir un bon contact mtalmtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. D Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique. D Ne pas raccorder plus dune lectrode ou plus dun cble de masse une mme borne de sortie de soudage. OM-217 769 Page 5

Il reste une TENSION DC NON NGLIGEABLE dans les sources de soudage onduleur quand on a coup lalimentation.
D Arrter les convertisseurs, dbrancher le courant lectrique et dcharger les condensateurs dalimentation selon les instructions indiques dans la partie Entretien avant de toucher les pices.

LE SOUDAGE peut provoquer un in cendie ou une explosion.

Le soudage effectu sur des conteneurs ferms tel que des rservoirs, tambours ou des conduites peu provoquer leur clatement. Des tincelles peuven tre projetes de larc de soudure. La projection dtincelles, des pice chaudes et des quipements chauds peut provoquer des incendies e des brlures. Le contact accidentel de llectrode avec des objet mtalliques peut provoquer des tincelles, une explosion, un surchauf fement ou un incendie. Avant de commencer le soudage, vrifier e sassurer que lendroit ne prsente pas de danger. D Dplacer toutes les substances inflammables une distance de 10,7 m de larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec des protections homologus. D Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables. D Se protger et dautres personnes de la projection dtincelles et de mtal chaud. D Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et des ouvertures. D Surveiller tout dclenchement dincendie et tenir un extincteur proximit. D Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct. D Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de scurit). D Ne soudez pas si lair ambiant est charg de particules, gaz, ou vapeurs inflammables (vapeur dessence, par exemple). D Brancher le cble de masse sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques dlectrocution, dtincelles et dincendie. D Ne pas utiliser le poste de soudage pour dgeler des conduites geles. D En cas de non utilisation, enlever la baguette dlectrode du portelectrode ou couper le fil la pointe de contact. D Porter des vtements de protection dpourvus dhuile tels que des gants en cuir, une chemise en matriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. D Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes. D Une fois le travail achev, assurezvous quil ne reste aucune trace dtincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupecircuits appropris. Ne pas augmenter leur puissance; ne pas les ponter. D Une fois le travail achev, assurezvous quil ne reste aucune trace dtincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupecircuits appropris. Ne pas augmenter leur puissance; ne pas les ponter. D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit.

DES PICES CHAUDES peuvent provoquer des brlures graves.

D Ne pas toucher mains nues les parties chaudes. D Prvoir une priode de refroidissement avant de travailler lquipement. D Ne pas toucher aux pices chaudes, utiliser les outils recommands et porter des gants de soudage et des vtements pais pour viter les brlures.

LES FUMES ET LES GAZ peuvent tre dangereux.

Le soudage gnre des fumes et des gaz. Leur inhalation peut tre dangereux pour votre sant. D Eloigner votre tte des fumes. Ne pas respirer les fumes. D lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau de larc pour lvacuation des fumes et des gaz de soudage. D Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approuv. D Lire et comprendre les spcifications de scurit des matriaux (MSDS) et les instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs. D Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger. D Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants. D Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien ventil, et en portant un respirateur alimentation dair. Les revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques en cas de soudage.

LES RAYONS DE LARC peuvent pro voquer des brlures dans les yeux e sur la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intense (ultraviolets et infrarouges) susceptibles de provoquer des brlure dans les yeux et sur la peau. Des tincelles sont projetes pendant le soudage. D Porter un casque de soudage approuv muni de verres filtrants appropri pour protger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). D Porter des lunettes de scurit avec crans latraux mme sous votre casque. D Avoir recours des crans protecteurs ou des rideaux pour protger les autres contre les rayonnements les blouissements et les tincelles ; prvenir toute personne sur les lieux de ne pas regarder larc. D Porter des vtements confectionns avec des matires rsistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. OM-217 769 Page 6

DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
D Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrent des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de scurit avec crans latraux ou un cran facial.

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

D Fermer lalimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu.

D Protger les bouteilles de gaz comprim dune chaleur excessive, des chocs mcaniques, des dommages physiques, du laitier, des flammes ouvertes, des tincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de se renverser. D Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques. D Ne jamais placer une torche de soudage sur une bouteille gaz. D Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille. D Ne jamais souder une bouteille pressurise risque dexplosion. D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et raccords convenables pour cette application spcifique ; les maintenir ainsi que les lments associs en bon tat. D Dtourner votre visage du dtendeur-rgulateur lorsque vous ouvrez la soupape de la bouteille. D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque la bouteille est utilise ou quelle est relie pour usage ultrieur. D Utiliser les quipements corrects, les bonnes procdures et suffisamment de personnes pour soulever et dplacer les bouteilles. D Lire et suivre les instructions sur les bouteilles de gaz comprim, lquipement connexe et le dpliant P-1 de la CGA (Compressed Gas Association) mentionn dans les principales normes de scurit.

LES CHAMPS MAGNETIQUES peuvent affecter des implants mdicaux.

D Porteur de simulateur cardiaque ou autre implants mdicaux, rester distance. D Les porteurs dimplants doivent dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.

LE BRUIT peut endommager loue.

Le bruit des processus et des quipements peut affecter loue. D Porter des protections approuves pour les oreilles si le niveau sonore est trop lev.

LES BOUTEILLES peuvent exploser si elles sont endommages.

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

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

Risque DINCENDIE OU DEXPLOSION.
D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables. D Ne pas installer lappareil proximit de produits inflammables. D Ne pas surcharger linstallation lectrique sassurer que lalimentation est correctement dimensionne et protge avant de mettre lappareil en service.

LES TINCELLES VOLANTES risquent de provoquer des blessures.

D Porter un cran facial pour protger le visage et les yeux. D Affter llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manuvre est excuter dans un endroit sr lorsque lon porte lquipement homologu de protection du visage, des mains et du corps. D Les tincelles risquent de causer un incendie loigner toute substance inflammable.

LA CHUTE DE LAPPAREIL peut blesser.

D Utiliser lanneau de levage uniquement pour soulever lappareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. D Utiliser un quipement de levage de capacit suffisante pour lever lappareil. D En utilisant des fourches de levage pour dplacer lunit, sassurer que les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pices. D Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des cartes de circuits imprimes.

LEMPLOI EXCESSIF peut CHAUFFER LQUIPEMENT.

SURDES ORGANES MOBILES peuvent provoquer des blessures.

D Ne pas sapprocher des organes mobiles. D Ne pas sapprocher des points de coincement tels que des rouleaux de commande. OM-217 769 Page 7

D Prvoir une priode de refroidissement ; respecter le cycle opratoire nominal. D Rduire le courant ou le facteur de marche avant de poursuivre le soudage. D Ne pas obstruer les passages dair du poste.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gchette avant den avoir reu linstruction. D Ne pas diriger le pistolet vers soi, dautres personnes ou toute pice mcanique en engageant le fil de soudage.

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer des interfrences.

D Le rayonnement haute frquence (H.F.) peut provoquer des interfrences avec les quipements de radionavigation et de communication, les services de scurit et les ordinateurs. D Demander seulement des personnes qualifies familiarises avec des quipements lectroniques de faire fonctionner linstallation. D Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interfrences rsultant de linstallation. D Si le FCC signale des interfrences, arrter immdiatement lappareil.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Sabstenir de toucher des organes mobiles tels que des ventilateurs. D Maintenir ferms et verrouills les portes, panneaux, recouvrements et dispositifs de protection. D Seules des personnes qualifies sont autorises enlever les portes, panneaux, recouvrements ou dispositifs de protection pour lentretien. D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand lentretien est termin et avant de rebrancher lalimentation lectrique.

LE SOUDAGE LARC risque de provoquer des interfrences.

D Lnergie lectromagntique risque de provoquer des interfrences pour lquipement lectronique sensible tel que les ordinateurs et lquipement command par ordinateur tel que les robots. Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement. Pour rduire la possibilit dinterfrence, maintenir les cbles de 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 quipement lectronique sensible. Veiller ce que ce poste de soudage soit pos et mis la terre conformment ce mode demploi. En cas dinterfrences aprs avoir pris les mesures prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

D D D D D

LIRE LES INSTRUCTIONS.

D Lisez le manuel dinstructions avant lutilisation ou la maintenance de lappareil. D Nutiliser que les pices de rechange recommandes par le constructeur. D Effectuer rgulirement le contrle et lentretien de linstallation. D Maintenir soigneusement ferms les portes et les panneaux des sources de haute frquence, maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour rduire les interfrences ventuelles.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent des fumes et des gaz qui contiennent des produits chimiques dont ltat de Californie reconnat quils provoquent des malformations congnitales et, dans certains cas, des cancers. (Code de sant et de scurit de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composs base de plomb, produits chimiques dont ltat de Californie reconnat quils provoquent des cancers et des malformations congnitales ou autres problmes de procration. Se laver les mains aprs manipulation. Pour les moteurs essence : Les gaz dchappement des moteurs contiennent des produits chimiques dont ltat de Californie reconnat quils provoquent des cancers et des malformations congnitales ou autres problmes de procration. Pour les moteurs diesel : Les gaz dchappement des moteurs diesel et certains de leurs composants sont reconnus par ltat de Californie comme provoquant des cancers et des malformations congnitales ou autres problmes de procration.

OM-217 769 Page 8

2-5. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (tlphone : 1-877-413-5184, site Internet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (tlphone : 1-877-413-5184, site Internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, 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, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (tlphone : 703-788-2700, site Internet : www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, 5060 Mississauga, Ontario, Canada L4W 5NS (tlphone : 800-463-6727 ou Toronto 416-747-4044, site Internet : www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 11 West 43rd Street, New York, NY 10036-8002 (tlphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureaux rgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF

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

OM-217 769 Page 9

OM-217 769 Page 10

SECTION 3 DEFINITIONS
3-1. Manufacturers Warning Label Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 Electric shock from welding electrode or wiring can kill. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Protect yourself from electric shock by insulating yourself from work and ground. Disconnect input plug or power before working on machine. Breathing welding fumes can be hazardous to your health. Keep your head out of the fumes. Use forced ventilation or local exhaust to remove the fumes. Use ventilating fan to remove fumes. Welding sparks can cause explosion or fire. Keep flammables away from welding. Do not weld near flammables. Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Do not weld on drums or any closed containers. Arc rays can burn eyes and injure skin. Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or welding. Do not remove or paint over (cover) the label.

1.2 1.3 2 1 1.1 1.2 1.3 2.1 2.2 2.3 2 2.1 2.2 2.3 3 3.1 3.2

3.1

3.2

3.3

3.3 4 4.1 4

+
6

4.1

5 6
S-179 310

1/96

OM-217 769 Page 11

1 2 3 1 2 3 4 5 6 4 V > 60 s V 5
S-179 190-A

Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 60 seconds after power is turned off before working on unit, OR Check input capacitor voltage, and be sure it is near 0 before touching any parts.

4/96

1 2 1 2 3 4 5 3

4 5

S-179 304-A

Warning! Watch Out! There are possible hazards as shown by the symbols. When power is applied failed parts can explode or cause other parts to explode. Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Always wear long sleeves and button your collar when servicing unit. After taking proper precautions as shown, connect power to unit.

4/96

1 1 2 3

= <60

4 5

Warning! Watch Out! There are possible hazards as shown by the symbols. Falling equipment can cause injury and damage to unit. Always lift and support unit using both handles. Keep angle of lifting device less than 60 degrees. Use a proper cart to move unit. Do not use one handle to lift or support unit.

S-179 309-A

5
1/96

OM-217 769 Page 12

3-2. Manufacturers Rating Label

223 643-B

3-3. Symbols And Definitions

Amperage

Panel

Alternating Current (AC)

Voltage

Output

Circuit Breaker Gas Tungsten Arc Welding Positive

Remote

On

Off Direct Current (DC)

Negative

Voltage Input Protective Earth (Ground)

Inductance

Constant Current

Constant Voltage

Foot Control

Line Connection Three Phase Static Frequency ConverterTransformerRectifier

Arc Force

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

U0 Hz I1max

Rated No Load Voltage (Average)

Hertz

U1 IP I1eff

Primary Voltage

Degree Of Protection Lift-Arc Trigger Hold Operation (GTAW) Maximum Effective Supply Current

U2 I2

Conventional Load Voltage Rated Welding Current

X %

Duty Cycle

Percent

Pulsed

Single Phase

Three Phase

Rated Maximum Supply Current

Increase

Lift-Arc Operation (GTAW)

OM-217 769 Page 13

SECTION 4 INSTALLATION
4-1. Specifications
Maximum Open-Circuit Voltage DC Amperes Input at Rated Load Output 50/60 Hz 400 V
23 17.0 (0.15*)

Rated Welding Output

300 A @ 32 Volts DC, 60% Duty Cycle *While idling

Voltage Range

Amperage Range

IP Rating

KVA
12.4 (0.09*)

KW
11.5 (0.04*)

10 35

5 400

90

4-2. 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, a Help message is displayed (see Section 6-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE Exceeding duty cycle can damage unit and void warranty.

60% Duty Cycle

6 Minutes Welding

4 Minutes Resting

Overheating 0 15 Minutes OR Reduce Duty Cycle

Ref. SA-178 651

OM-217 769 Page 14

4-3. Volt-Ampere Curves

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown.

A. CC Mode

B. CV Mode

ARC CONTROL

va_curve1 4/95 SA-178 652 / SA-178 653

OM-217 769 Page 15

4-4. Dimensions And Weight

Hole Layout Dimensions F A 11-3/4 in (298 mm) A E G 24 in i (610 mm)

1-11/16 in (42 mm)

17 in (432 mm)

15-3/4 in (400 mm)

D C

19-3/32 in (485 mm) 12-1/2 in (318 mm)

8-11/16 in (221 mm) B

804 801-A

F G

1-17/32 in (39 mm) 1/4-20 UNC -2B thread Weight 76 lb (34.6 kg)

4-5. Selecting a Location

Movement 1 1 1 2 Lifting Handles Hand Cart Use handles to lift unit.

Do not move or operate unit where it could tip.

Use cart or similar device to move unit. 3 Rating Information Use rating information on rear panel to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply. 2

Location

4 3 18 in (460 mm)

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

18 in (460 mm)

Ref. ST-151 556 / 801 192

OM-217 769 Page 16

4-6. 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 Output Terminals

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

! !

Turn off power before connecting to weld output terminals. Do not use worn, damaged, undersized, or poorly spliced cables. 100 150 200 250 300 350

100 ft (30 m) or Less

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

350 ft 400 ft (105 m) (120 m)

4 (20) 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 2/0 (70) 3/0 (95)

4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120)

4 (20) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70)

3 (30) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95)

2 (35) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120)

1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120)

1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120)

400 500 600

Output Receptacles

* This

chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
S-0007-F

**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 ***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

OM-217 769 Page 17

4-7. Remote 14 Receptacle Information

Socket* 24 VOLTS AC
A B K J I H F G A B I J C

Socket Information
24 volts ac. Protected by circuit breaker CB2. Contact closure to A completes 24 volts ac contactor control circuit. 115 volts ac. Protected by circuit breaker CB1. Contact closure to I completes 115 volts ac contactor control circuit. Output to remote control; 0 to +10 volts dc, +10 volts dc in MIG mode. Remote control circuit common. 0 to +10 volts dc input command signal from remote control. Voltage feedback; +1 volt dc per 10 output receptacle volts. Current feedback; +1 volt dc per 100 amperes. CC/CV select Circuit common for 24 and 115 volts ac circuits. Chassis common.

C L N D M E

115 VOLTS AC

REMOTE OUTPUT CONTROL

D E H

AMPERAGE VOLTAGE
ST-801 192

A/V

F M G

GND
*The remaining sockets are not used.

4-8. Electrical Service Guide

NOTICE INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source. NOTICE Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 50/60 Hz Three Phase Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes
1

400 18 Time-Delay 2 Normal Operating 3

4

20 25 14 133 (41) 14

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG 4

Reference: 2005 National Electrical Code (NEC) (includes article 630) 1 Consult factory for circuit breaker applications. 2 Time-Delay fuses are UL class RK5 . 3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. OM-217 769 Page 18

4-9. Connecting 3-Phase Input Power 3

= GND/PE Earth Ground 4

! ! !
7

Installation must meet all National and Local Codes have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. Input Power Cord. Disconnect Device (switch shown in the OFF position) Green Or Green/Yellow Grounding Conductor Disconnect Device Grounding Terminal Input Conductors (L1, L2 And L3) Disconnect Device Line Terminals

For Three-Phase Operation 1 2 2 3 4 5 6 5

L1 3 6 L2 L3

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.

Over-Current Protection

Select type and size of over-current protection using Section 4-8 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. 1

Tools Needed:

ST-144 221 / ST-801 192 / 803 766-A

OM-217 769 Page 19

SECTION 5 OPERATION
5-1. Front Panel Controls

6
Ref. ST-175 086

Power On/Off Switch fan motor is thermostatically controlled and only runs when cooling is needed.

. The
2 3 4 5

Voltmeter (see Section 5-2) Ammeter (see Section 5-2) Voltage/Amperage Adjustment Control Mode Switch

The Mode switch setting determines both the process and output On/Off control (see Section 5-3. Source of control (panel or remote) for the amount of output is selected on the Voltage/Amperage Control switch. For Air Carbon Arc (CAC-A) cutting and gouging, place switch in Stick position. For OM-217 769 Page 20

best results, place Inductance/Dig control in the maximum position. 6 Voltage/Amperage Control Switch For front panel control, place switch in Panel position. For remote control, make connections to Remote 14 receptacle, and place switch in Remote position. In most modes, remote control is a percent of the Voltage/Amperage Adjustment control setting (the value selected on Voltage/Amperage Adjustment control is maximum available on remote). In the MIG mode, remote control provides full range of unit output regardless of V/A Adjust control setting. 7 Inductance/Dig Control Control adjusts Dig when a Stick (SMAW) welding position is selected on mode switch.

When set lower, short-circuit amperage at low arc voltage is the same as normal welding amperage. When set higher, short-circuit amperage is increased at low arc voltage to assist with arc starts as well as reduce sticking while welding (see volt-ampere curves in Section 4-3). Select setting best suited for application. Control adjusts inductance when a MIG (GMAW) position is selected on the mode switch. Inductance determines the wetness of the weld puddle. When set higher, wetness (puddle fluidity) increases. When pulsed MIG, or one of the TIG (GTAW) processes is selected, this control is not functional.

5-2. Meter Functions . The meters display the actual weld output values for approximately three seconds after the arc is broken.

Mode

Meter Reading At Idle

V A

Scratch Start TIG (GTAW)

80.0
Actual Volts (OCV) V

85
Preset Amps A

Lift-Arc TIG (GTAW)

7.5
Blank V

85
Preset Amps A

TIG (GTAW) Blank V MIG (GMAW)

85
Preset Amps A

24.5
Preset Volts V Blank A

Pulsed MIG (GMAW-P)

PPP
Pulse Display V

PPP
Pulse Display A

Remote Control SMAW

85
Blank V Preset Amps A

Panel Control SMAW

80.0
Actual Volts (OCV) V

85
Preset Amps A

Voltage-Sensing Wirefeeder

80.0
Flashes (OCV) And Preset Blank

OM-217 769 Page 21

5-3. Mode Switch Settings . The SMAW modes provide the Adaptive Hot Start feature, which automatically increases the output amperage at the start of a weld should the
start require it. This eliminates electrode sticking at arc start.

Mode

Output Control

Select: Scratch Start TIG (GTAW) Weld

or

Amp

Lift-Arc TIG (GTAW)

Select: Weld

or

Amp

TIG (GTAW) With HF Unit, Pulsing Device, Or Remote Control

Select: Requires:

or

Amp Control

Select: MIG (GMAW) Requires: Pulsed MIG (GMAW-P) (Requires an external pulsing device.)

or Feeder

Volt

Select: Requires:

Volt Feeder or Control

Select: Remote Control SMAW Requires:

or

Amp Control

Panel Control SMAW

Select: Weld

or

Amp

Voltage-Sensing Wirefeeder

Select: Requires:

or Feeder

Volt

OM-217 769 Page 22

5-4. Lift-Arc TIG Procedure

With Process Switch in the Lift-Arc TIG position, start an arc as follows: 1 1 2 2 TIG Electrode Workpiece

Touch

12 Seconds

Touch tungsten electrode to workpiece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted. Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state output contactor does not energize until after electrode is touching workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated.

Do NOT Strike Like A Match!

Ref. S-156 279

Notes

OM-217 769 Page 23

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance
!
Disconnect power before maintaining.

. Maintain more often

during severe conditions.

3 Months
Replace Damaged Or Unreadable Labels Repair Or Replace Cracked Cables Replace Cracked Torch Body

Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections

6 Months
Blow Out Inside

6-2. 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.

ST-801 192

OM-217 769 Page 24

6-3. Voltmeter/Ammeter Help Displays

HE.L
V

P 0
A

HE.L
V

P 5
A

HE.L
V

P 1
A

HE.L
V

P 6
A

HE.L
V

P 2
A

HE.L
V

P 7
A

HE.L
V

P 3
A

HE.L
V

P 8
A

HE.L

P 4

10

HE.L

P 9

. All directions are in reference to the front

of the unit. All circuitry referred to is located inside the unit. 1 Help 0 Display Indicates a shorted thermistor RT2 on the left side of the unit. If this display is shown, contact a Factory Authorized Service Agent. 2 Help 1 Display Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent. 3 Help 2 Display Indicates a malfunction in the thermal protection circuitry located on the left side of the unit. If this display is shown, contact a Factory Authorized Service Agent. 4 Help 3 Display Indicates the left side of the unit has overheated. The unit has shut down to allow the

fan to cool it (see Section 4-2). Operation will continue when the unit has cooled. 5 Help 4 Display

shown, have an electrician check the input voltage. 8 Help 7 Display Indicates that the input voltage is too high and the unit has automatically shut down. Operation will continue when the voltage is within the acceptable upper range limit (15% above the applicable input voltage). If this display is shown, have an electrician check the input voltage. Help 7 can also indicate a bus voltage imbalance. 9 Help 8 Display Indicates a malfunction in the secondary power circuit of the unit. If this display is shown, contact a Factory Authorized Service Agent. 10 Help 9 Display Indicates a shorted thermistor RT1 on the right side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

Indicates a malfunction in the thermal protection circuitry located on the right side of the unit. If this display is shown, contact a Factory Authorized Service Agent. 6 Help 5 Display

Indicates the right side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 4-2). Operation will continue when the unit has cooled. 7 Help 6 Display

Indicates that the input voltage is too low and the unit has automatically shut down. Operation will continue when the voltage is within the acceptable lower range limit (15% below the applicable input voltage). If this display is

OM-217 769 Page 25

6-4. Troubleshooting

Trouble
No weld output; unit completely inoperative erative.

Remedy
Place line disconnect switch in On position (see Section 4-9). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-9). Check for proper input power connections (see Section 4-9).

No weld output; meter display On.

If using remote control, be sure Mode Selector switch is in a position that provides output control at Remote 14 receptacle. Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 4-2).

Erratic or improper weld output.

Use proper size and type of weld cable (see Section 4-6). Clean and tighten all weld connections.

No 110 volts ac output at duplex receptacle, Remote 14 receptacle. No 24 volts ac output at Remote 14 receptacle.

Reset circuit breaker CB1. Reset circuit breaker CB2.

OM-217 769 Page 26

SECTION 7 ELECTRICAL DIAGRAM

217 766-B

Figure 7-1. Circuit Diagram For Welding Power Source

OM-217 769 Page 27

OM-217 769 Page 28 19 17 18 20 22 23 16 15 14 8 62 9 10 7 11 4 60 5 6 12 13 21 24 44 43 48 49 50 52 54 53 47 51 45 46 36 35 34 9 42 41 11 40 25 26 27 28 39 38 29 37 12 32 30 31

61

SECTION 8 PARTS LIST

Figure 8-1. Parts Assembly

59

58

20

56

57

55

803 687-C

Item No.

Dia. Mkgs.

Part No.

Description Figure 8-1. Parts Assembly

Quantity

. . . 1 . . . . . . . . . . . . . . +175 148 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 175 256 . . Insulator, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . . . . . . . . . . . . . 195 585 . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 3 . . . . . . . . . . . . . . . 179 309 . . Label, Caution Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 4 . . . . . HD1 . . . . . 182 918 . . Transducer, Current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 5 . . . . . . . . . . . . . . . 203 342 . . Bus Bar, Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 6 . . . . . . . . . . . . . . . 203 341 . . Bus Bar, Output Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 7 . . . . . . . . . . . . . . . 181 853 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 8 . . . . . D1,2 . . . . . 201 531 . . Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 9 . . . . . . . . . . . . . . . 179 276 . . Bushing, Snap-In Nyl 1.000 ID x 1.375Mtg Hole . . . . . . . . . . . . . . . . . . . . 2 . . . 10 . . . C5,6 R1 . . . 175 194 . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 11 . . . . RT1,2 . . . . 173 632 . . Thermistor, NTC 30K Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 12 . . . . . . . . . . . . . . . 185 836 . . Label, Warning Exploding Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 13 . . . . . . . . . . . . . . +183 551 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 14 . . . . . . . . . . . . . . . 234 126 . . Nut, Conduit 1.000 Npt Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 15 . . . . . CB1 . . . . . 089 807 . . Circuit Breaker, Man Reset 1P 2.5A 250VAC . . . . . . . . . . . . . . . . . . . . . . 1 . . . 16 . . . . . CB2 . . . . . 083 432 . . Circuit Breaker, Man Reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 17 . . . . . . . . . . . . . . . 206 460 . . Panel, Rear (Without Aux. Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 18 . . . . . . . . . . . . . . . 213 099 . . Bushing, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 178 563 . . Nut, Nylon 1.000 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 186 439 . . Ftg, Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 210 346 . . Cable, Pwr 6mm 4/C 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . Plate, Ident Rear (Order By Model And Serial Number) . . . . . . . . . . . . . 1 . . . 20 . . . . . . . . . . . . . . . 175 138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 21 . . . . . . . . . . . . . . . 192 853 . . Bracket, Mtg Contactor/Capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 22 . . . . . PC1 . . . . . 215 042 . . Circuit Card, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG2 . . . . 131 056 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG3 . . . . 130 203 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG5 . . . . 115 091 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG7 . . . . 115 093 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 23 . . . . RC10 . . . . 166 679 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . . T2 . . . . . . 217 322 . . Transformer, Control 200/400VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 25 . . . . . . . . . . . . . . +207 727 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 26 . . . . . . . . . . . . . . . 153 403 . . Bushing, Snap-In Nyl .750 Id X 1.000Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 27 . . . . . . . . . . . . . . . 177 547 . . Bushing, Snap-In Nyl 1.125Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 28 . . . . . CT1 . . . . . 175 199 . . Transformer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 29 . . . . . . . . . . . . . . . 025 248 . . Stand-Off, Insul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 30 . . . . . C1 . . . . . 188 446 . . Capacitor, Polyp Film .5Uf 900VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 31 . . . . . C3,4 . . . . . 192 935 . . Capacitor, Elctlt 2700Uf 450VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 32 . . . . . PC2 . . . . . 212 210 . . Circuit Card, Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG13 . . . . 131 204 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . PLG14,21 . . 115 093 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 33 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . 175 140 . . Bracket, Di/Dt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 35 . . . . . . . . . . . . . . . 175 482 . . Coil, Di/Dt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 36 . . . . . . . . . . . . . . . 109 056 . . Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 37 . . . . . SR1 . . . . . 179 629 . . Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . PM1,2 . . . . 233 043 . . Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 39 . . . . . . Z1 . . . . . . 173 570 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 40 . . . . . . L1 . . . . . . 173 563 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 41 . . . . . . . . . . . . . . . 207 725 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 42 . . . . . . T1 . . . . . . 179 616 . . Transformer, Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 43 . . . . . . . . . . . . . . . 207 467 . . Heat Sink, Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 44 . . . . . . . . . . . . . . . 175 255 . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 175 969 . . Insulator, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . 181 197 . . Gasket, Di/Dt Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 45 . . . . . . . . . . . . . . . 173 693 . . Foot, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 46 . . . . . . . . . . . . . . . 176 736 . . Screw, Mtg Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OM-217 769 Page 29

Item No.

Dia. Mkgs.

Part No.

Description Figure 8-1. Parts Assembly (Continued)

Quantity

. . . 47 . . . . . . . . . . . . . . . 175 132 . . . . . 48 . . . . . PC3 . . . . . 219 820 . . . . . . . . . . . . PLG11 . . . . 115 091 . . . . . 49 . . . . . FM . . . . . 175 084 . . . . . 50 . . . . . RC1 . . . . . 186 706 . . . . . 51 . . . . . . . . . . . . . . . 178 548 . . . . . 52 . . . . . C7,8 . . . . . 222 488 . . . . . 53 . . . . . . . . . . . . . . . 185 732 . . . . . 54 . . . . . . . . . . . . . . . 129 525 . . . . . . . . . . . . . . . . . . . . . . . 145 088 . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 070 590 . . . . . 56 . . . . . . . . . . . . . . . 174 992 . . . . . 57 . . . . . . . . . . . . . . . 175 855 . . . . . 58 . . . . . . . . . . . . . . . 174 991 . . . . . 59 . . . . . . . . . . . . . . . 176 226 . . . . . 60 . . . . . . S1 . . . . . 231 191 . . . . . 61 . . . . . . . . . . . . . . . 179 310 . . . . . 62 . . . . . . . . . . . . . . . 199 840 . .

Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan, Muffin 24VDC 3000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receptacle, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receptacle, Twlk Insul Fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit, Connection Dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . Tubing, Gl Acryl .325 (Order By Ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knob, Pointer .840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knob, Pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch, Tgl 3Pst 50A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 2 2 1 2 1 1 1ft 2 1 2 1 1 2 2

+When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-217 769 Page 30

Effective January 1, 2007 (Equipment with a serial number preface of LH or newer)

Warranty Questions?

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

Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls its original retail purchaser that new Miller equipment sold after * APT & SAF Model Plasma Cutting Torches the effective date of this limited warranty is free of defects in * Remote Controls material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Accessory (Kits) WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor) WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns Within the warranty periods listed below, Miller will repair or * Canvas Covers replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Millers True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.) Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. 1. 2. 5 Years Parts 3 Years Labor

2.

3.

* * * * * * * * *

Original main power rectifiers Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi-Automatic and Automatic Wire Feeders Inverter Power Sources (Unless Otherwise Stated) Water Coolant Systems (Integrated) Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) Motor Driven Guns (w/exception of Spoolmate Spoolguns) Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources, Coolers, and Electronic Controls/Recorders Water Coolant Systems (Non-Integrated) Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Spot Welders Load Banks Arc Stud Power Sources & Arc Stud Guns Racks Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.) Bernard-Branded Mig Guns (No Labor) Weldcraft-Branded TIG Torches (No Labor) Subarc Wire Drive Assemblies

3 Years Parts and Labor

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

3.

1 Year Parts and Labor Unless Specified

* * * * * * * * * * * * * * * *

* * *
4. 5.

6 Months Batteries 90 Days Parts

MIG Guns/TIG Torches and Subarc (SAW) Guns

miller_warr 200701

Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)

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 Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International HeadquartersUSA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066
www.MillerWelds.com

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