OM-188 304AB Processes

May 2005

MIG (GMAW) Welding Pulsed MIG (GMAW-P) Stick (SMAW) Welding

Description

Arc Welding Power Source With Built-In Synergic Control

Invision 354MP
R

(230/460 And 460/575 Volt Models)

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.

Mil_Thank 4/05

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. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de lappareil. . . . . . . . . . . . 2-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Weld Output Receptacles And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Optional 115 Volt AC Duplex Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Example Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Synergic Controls And Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Initial Display, Manual Pulse MIG Mode, MIG Mode, And Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Choosing Pulse Programs And Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. How Manual Pulsed MIG Waveform Components Affect Arc And Burn-Off Rate . . . . . . . . . . . . . . . . . SECTION 6 PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Overview Of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Individual Program Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 3 4 4 5 5 5 7 8 8 9 9 9 10 11 11 12 13 13 14 15 16 17 17 18 19 20 21 22 23 24 25 25 25 30 30 30 31 32 32 34 36

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

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Y Warning: Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

. Means Note; not safety related. 1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. Y During operation, keep everybody, especially children, away.

D D D D D D D D D D D D

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. D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first double-check connections. D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal.

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

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs) and the 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. OM-188 304 Page 1

ARC RAYS can burn eyes and skin.

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

BUILDUP OF GAS can injure or kill.

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

HOT PARTS can cause severe burns.

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

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

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

CYLINDERS can explode if damaged.

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

FLYING METAL can injure eyes.

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

OM-188 304 Page 2

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 Miller/Hobart replacement parts.

H.F. RADIATION can cause interference.

OVERUSE can cause OVERHEATING

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

D D

STATIC (ESD) can damage PC boards.

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

D D

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

ARC WELDING can cause interference.

MOVING PARTS can cause injury.

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

WELDING WIRE can cause injury.

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

D D D

D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Y Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Gasoline Engines: Y Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Y Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. OM-188 304 Page 3

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). 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, 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, Suite 1004, Arlington, VA 222024102 (phone: 7034120900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 8004636727 or in Toronto 4167474044, website: www.csainternational.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 100368002 (phone: 2126424900, 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, 1 Battery March Park, Quincy, MA 022699101 (phone: 6177703000,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 (there are 10 Regional Officesphone for Region 5, Chicago, is 3123532220,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. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor before welding or going near welding operations. If cleared by your doctor, then following the above procedures is recommended.

OM-188 304 Page 4

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

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Y 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 procdure comporte des risques possibles ! Les dangers ventuels sont reprsents par les symboles graphiques joints.

Y Indique un message de scurit particulier

. Signifie NOTE ; nest pas relatif la scurit.

2-2. Dangers relatifs au soudage larc
Y 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. Y Seul un personnel qualifi est autoris installer, faire fonctionner, entretenir et rparer cet appareil. Y Pendant le fonctionnement, maintenir distance toutes les personnes, notamment les enfants de lappareil.

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 les dangers.

D Vrifier frquemment le cordon dalimentation afin de sassurer quil D D D D D D D D D D 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 D D D D D

D D

trous. 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. Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. 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 ( 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.

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.

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

LES FUMES ET LES GAZ peuvent tre dangereux.

Le soudage gnre des fumes et des gaz. Leur inhalation peut tre dangereuse pour la sant. D Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces vaD lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau de D Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approuD Lire et comprendre les spcifications de scurit des matriaux (MSDS) et
v. 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. larc pour lvacuation des fumes et des gaz de soudage. peurs.

OM-188 304 Page 5

LES RAYONS DARC peuvent entraner des brlures aux yeux et la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brlures 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.

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.

DES PICES CHAUDES peuvent provoquer des brlures graves.

D Ne pas toucher des parties chaudes mains nues. D Prvoir une priode de refroidissement avant dutiliser le pistolet ou la torche. 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.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectu sur des conteneurs ferms tels que des rservoirs, tambours ou des conduites peut provoquer leur clatement. Des tincelles peuvent tre projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peuvent provoquer des incendies et des brlures. Le contact accidentel de llectrode avec des objets mtalliques peut provoquer des tincelles, une explosion, une surchauffe ou un incendie. Avant de commencer le soudage, vrifier et 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 homologues. D Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables. D Se protger, ainsi que toute autre personne travaillant sur les lieux, contre les tincelles et le 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 Afin dliminer tout risque de feu, tre vigilant et garder toujours un extincteur la porte de main. 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 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 exempts dhuile tels que des gants en cuir, une veste rsistante, des pantalons sans revers, des bottes et un casque. D Avant de souder, retirer toute substance combustible de ses poches telles quun allumeur au butane ou des allumettes. D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B pour travaux de soudage et prvoir un dtecteur dincendie et un extincteur proximit.

LES CHAMPS MAGNTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, rester distance. D Les porteurs dun stimulateur cardiaque doivent dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

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. 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.

DES PARTICULES VOLANTES peuvent blesser 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.

OM-188 304 Page 6

2-3.

Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLOSION. 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.

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.

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.

LIRE LES INSTRUCTIONS.

D Lire le manuel dutilisation avant dutiliser ou dintervenir sur lappareil. D Utiliser uniquement des pices de rechange Miller/Hobart.

LEMPLOI EXCESSIF peut CHAUFFER LQUIPEMENT.

SUR-

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

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

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.

D D D D D

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 PC.

LE SOUDAGE LARC risque de provoquer des interfrences.

D Lnergie lectromagntique peut gner le fonctionnement dappareils lectroniques comme des ordinateurs et des robots. D 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.

DES 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. D D D D

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.

2-4.

Proposition californienne 65 Avertissements

Pour les moteurs essence : Y 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 : Y 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-188 304 Page 7

Y 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) Y 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.

2-5.

Principales normes de scurit

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (tlphone : 800-463-6727 ou Toronto 416-747-4044, site Internet : www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 11 West 42nd Street, New York, NY 10036-8002 (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, 1 Battery March Park, 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 (il y a 10 bureaux rgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, site Internet : www.osha.gov).

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, 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 1004, Arlington, VA 22202-4102 (tlphone : 703-412-0900, site Internet : www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 178 Rexdale

2-6.

Information EMF
1. Maintenir les cbles ensemble en les tordant ou en les enveloppant. 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 stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur mdecin avant de souder ou dapprocher des oprations de soudage. Si le mdecin approuve, il est recommand de suivre les procdures prcdentes.

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 :

OM-188 304 Page 8

SECTION 3 INTRODUCTION
3-1. Specifications
RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Load Voltages and Class I Rating 230 V 30.5 (0.21*) 47.4 (0.34*) 460 V 18.9 (0.10*) 24.5 (0.14*) KVA** 12.2 (0.09*) 11.3 (0.09*) KW** 11.6 (0.04*) 7.6 (0.04*)

Rated Output at 60% Duty Cycle 300 A at 32 VDC, 3-Phase 225 A at 29 VDC, 1-Phase *While idling

Voltage Range in CV Mode 1035 V

Amperage Range in CC Mode 5400 A

Max. OpenCircuit Voltage 90 VDC

** Information based on 230 V, 3-phase input line.

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, a Help message is displayed (see Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. Y Exceeding duty cycle can damage unit and void warranty.

60% Duty Cycle

6 Minutes Welding Overheating 0

4 Minutes Resting

A or V
15

Minutes

OR Reduce Duty Cycle

sduty1 5/95 / SA-207 877

OM-188 304 Page 9

3-3. 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.

CC Mode

CV Mode

va_curve1 4/95 SA-188 537 / SA-178 653

OM-188 304 Page 10

SECTION 4 INSTALLATION
4-1. Selecting A Location

24 in (610 mm) Dimensions And Weight 76 lb (34.6 kg) 17 in (432 mm)

12-1/2 in (318 mm)

Movement Y Do not move or operate unit where it could tip.

1 2

Lifting Handles Hand Cart

Use handles to lift unit. 1 Use cart or similar device to move unit. 3 1 2 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply. Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20.

Location

18 in (460 mm) 3

18 in (460 mm)

loc_2 3/96 - Ref. ST-151 556 / ST-802 167

OM-188 304 Page 11

4-2. Weld Output Receptacles And Selecting Cable Sizes

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

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less Weld Output Terminals
Y Turn off power before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables. 100 150 200 250 300 350

150 ft (45 m)

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

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

Welding Amperes

10 60% Duty Cycle

60 100% Duty Cycle

10 100% Duty Cycle

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-188 304 Page 12

4-3. Remote 14 Receptacle Information

Socket* 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; +10 volts dc. Remote control circuit common. 0 to +10 volts dc input command signal from remote control. Current feedback; +1 volt dc per 100 amperes. Voltage feedback; +1 volt dc per 10 output receptacle volts. Circuit common for 24 and 115 volts ac circuits. Chassis common.

A B

24 VOLTS AC
I

A B I J C

H C L N D M G E F

115 VOLTS AC

REMOTE OUTPUT CONTROL

D E F H G K

AMPERAGE VOLTAGE GND

*The remaining sockets are not used.

A/V

4-4. Optional 115 Volt AC Duplex Receptacle And Circuit Breakers

1 115 V 10 A AC Receptacle Power is shared between duplex receptacle and Remote 14 receptacle (see Section 4-3). 2 1 Circuit Breaker CB1 CB1 protects duplex receptacle and 115 volt ac portion of Remote 14 receptacle from overload. 3 Circuit Breaker CB2 CB2 protects 24 volt ac portion of Remote 14 receptacle from overload. Press button to reset breaker.

ST-801 245-A

OM-188 304 Page 13

4-5. Electrical Service Guide

Y

CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow-

er source requires a CONTINUOUS supply of 60 Hz (+10%) power at +10% of rated input voltage. 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.

NOTE

Actual input voltage should not exceed 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not be available.
60 Hz Single Phase 230 53 460 27

60 Hz Three Phase Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 Normal Operating 3 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil 35 45 10 112 (34) 10 15 20 14 175 (53) 14 15 20 14 274 (83) 14 230 31 460 15 575 12

60 80 8 85 (26) 8

30 40 10 224 (68) 10

Reference: 1999 National Electrical Code (NEC) 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).

Notes

OM-188 304 Page 14

4-6. Connecting 1-Phase Input Power

Y Installation must meet all National and Local Codes have only qualified persons make this installation.

1
8

Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

=GND/PE Earth Ground 10

. The Auto-Link circuitry in this unit

7 9 1 2 3 1 1 4 5

automatically links the power source to the primary voltage being applied. A 230/460 unit can be connected to either 230 or 460 VAC input power. A 460/575 model can be connected to either 460 or 575 VAC input power.

L1 L2 3

Black And White Input Conductor (L1 And L2) Red Input Conductor Green Or Green/Yellow Grounding Conductor Insulation Sleeving Electrical Tape

2 3 6 5 4

Insulate and isolate red conductor as shown. 6 Input Power Cord. 7 Disconnect Device (switch shown in the OFF position) 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1 and L2 to disconnect device line terminals. 10 Overcurrent Protection Select type and size of overcurrent protection using Section 4-5 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:
2/04 - Ref. 802 136-A / 801 192

OM-188 304 Page 15

4-7. Connecting 3-Phase Input Power

Y Installation must meet all National and Local Codes have only qualified persons make this installation.

3
= GND/PE Earth Ground 4

Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

. The Auto-Link circuitry in this unit au7

tomatically links the power source to the primary voltage being applied. A 230/460 unit can be connected to either 230 or 460 VAC input power. A 460/575 model can be connected to either 460 or 575 VAC input power.

For Three-Phase Operation 2 1 2 3 L1 3 6 L2 L3 5 4 5 6 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

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.

Overcurrent Protection

Select type and size of overcurrent protection using Section 4-5 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:

2/04 - Ref. 802 136-A / 801 192

OM-188 304 Page 16

SECTION 5 OPERATION
5-1. Front Panel Controls
1 Power Switch amperage. 5 Trim Indicator Light 7

. The

fan motor is thermostatically controlled and only runs when cooling is needed. 2 Voltmeter (see Section 5-2) 3 Ammeter/Trim Indicator (see Section 5-2) 4 Ammeter Light Lights when display beneath is indicating

Lights when display beneath is indicating trim. 6 Output Adjust Control

Increment Push Button (see Section 5-4) 8 Decrement Push Button (see Section 5-4) 9 Display (see Section 5-4) 10 Select Push Button (see Section 5-4)

Controls various output values, depending on mode being used.

4 1 2 3

5 6

10

Ref. ST-187 841

OM-188 304 Page 17

5-2. Meter Functions

NOTE
Mode MIG

The meters display the actual weld output values for approximately three seconds after the arc is broken.
Meter Reading At Idle V A Meter Reading While Welding V A

24.5
Preset Volts V Blank Trim

24.5
Actual Volts V

250
Actual Amps A

Pulsed MIG Blank V Stick Contactor Remote Blank V Stick Contactor ON

50
Pulse Display A

24.5
Actual Volts V

250
Actual Amps A

85
Preset Amps A

24.5
Actual Volts V

85
Actual Amps A

80.0
Actual Volts (OCV) V

85
Preset Amps A

24.5
Actual Volts V

85
Actual Amps A

Manual Pulse

PPS

200

24.5
Actual Volts

85
Actual Amps

Pulses Per Second

OM-188 304 Page 18

5-3. Example Displays . Values shown are hypothetical.

The A (Amperage) and Trim lights illuminate as shown.

Amperage preset display for Stick welding mode.

Voltage preset display for MIG welding mode.

Display while welding.

Preset trim display for Pulse welding mode.

Preset pulses per second (PPS) display for Manual Pulse welding mode.

NOTE

The Stick mode provides 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.

OM-188 304 Page 19

5-4. Synergic Controls And Overview

Controls 1 2 Display Parameter Select Push Button

3 2

Press button to move > on display. The parameter indicated by > is selected. 3 Increment Push Button Press increment button to increase selected parameter. 4 Decrement Push Button to Press decrement button decrease selected parameter. See example at left. Overview The built-in synergic control provides four modes of operation:

1 4

Manual Pulse MIG control functions as a discrete pulsed MIG CC control. Mig control functions as a remote voltage control. Stick unit is placed in CC mode for SMAW welding. Synergic Pulser programs that use factory-entered values are used to control process. Setup screens (see Section 5-6) allow programs or modes to be made inaccessible (locked out) to the operator, and the language used in the displays (English, French, etc.) to be defined.

Example To select Program 7, set to Non Adaptive, and set Arc Length to 36, proceed as follows: Select top line by pressing Select push button until > is on top line. Press Increment button until Program 7 appears.

> P r g

0 3 5 A l

5 3 5 6

A r

A d a p t i v e

P u l s e

Press Select push button to select second line, and press Increment or Decrement button so Non Adaptive appears.

P r g

0 3 5 A l

5 3 5 6

A r

> N o n A d a p t i v e

P u l s e

Turn Output Adjust control to set arc length to 36.

36

OM-188 304 Page 20

5-5. Initial Display, Manual Pulse MIG Mode, MIG Mode, And Stick Mode
1 Software Program Number When power is applied, initial display with software number appears momentarily, and then last program to be viewed before control was shut down appears. 2 Manual Pulse MIG Mode The synergic control functions as a discrete pulsed MIG CC control in this mode. Select top line of display, and press Increment or Decrement button until Manual Pulse MIG is displayed. Select Amps Peak line, and use Increment or Decrement button to set peak amperage from 100400 amps, but always at least 1 amp more than background amperage. Select Amps Background line, and use Increment or Decrement button to set background amperage (min: 10 amps; max: 300 amps, but always at least 1 amp less than peak setting). Select ms Pulse Width line, and use Increment or Decrement button to set pulse width (1 - 5 ms, but max setting may be less depending on Frequency setting). Select Amps Start line, and use Increment or Decrement button to set starting amperage (150 - 530 amperes). This amperage value is used at the start of the weld or when an arc is restarted. Use Output Adjust control to set pulse frequency. The range is 30 300 pulses per second, but max setting may be less depending on Pulse Width setting. 3 MIG Mode The synergic control provides voltage control. 3 With > on top line, press Increment or Decrement button until MIG appears.

I N V I S I ON C O P Y R I GH T M I L L E R M f g

3 5 4 MP (C) 2 0 0 1

E l e c t r i c

C o . X X X X X X

2 With > on top line, press Increment or Decrement button until Manual Pulse MIG appears.

> P r g 1 3 3 4 6 7 8 1 . 7 3

M a n u a l P e a k

P u l s e

A m p s A m p s m s

B a c k g r o u n d P u l s e W i d t h

3 4 6
Display scrolls to show line 5.

A m p s A m p s m s A m p s

P e a k B a c k g r o u n d P u l s e S t a r t W i d t h

7 8 1 . 7 3 > 4 0 0

> P r g 1 4 2 5 %

M I G I n d u c t a n c e

Select top line of display, and press Increment or Decrement button until MIG is displayed. Select Inductance line, and use Increment or Decrement button to set inductance (0100% in increments of one). Use Output Adjust control to set voltage value (1035 volts). 4 Stick Mode In the Stick mode, the user can select contactor control (remote or On) and the Dig value. Select contactor control line and press Increment or Decrement button to select Remote contactor control or On. The contactor is On at all times when On is selected. Select Dig line, and and use Increment or Decrement button to set Dig value (min: 0%; max: 100%). Dig helps arc starting and reduces sticking while welding. The higher the dig value defined, the more the short-circuit amperage increases at low arc voltage.

4 With > on top line, press Increment or Decrement button until STICK appears.

> P r g 1 5

S T I C K R E MO T E

C o n t a c t o r 2 5 % D i g

OM-188 304 Page 21

5-6. Setup Screens

To access Setup screens: turn welding power source Off, press and hold Select push button, turn unit On, and hold push button down until initial screen leaves. 1 To exit Setup screens, turn welding power source Off and then On again. Parameters that are displayed when the Setup screens are exited are active.

S e t u p A c c e s s i b l e M a n u a l > O f f P r o g r a m s M i g

Accessible Programs Screen

P u l s e

Select second line of display, and press Increment or Decrement button until Accessible Programs is displayed. Select third line of display and press Increment or Decrement button to access each program and the three modes as desired. Select the fourth line and press Increment or Decrement button to define each option On (accessible) or Off (not accessible). Programs and modes that are defined Off are not shown when the operator scrolls through the displays in normal operation. 2 Language Screen Select second line of display, and press Increment or Decrement button until Language is displayed. Select third line of display and press Increment or Decrement button until desired language is shown. The choices are English, French, Italian, Spanish, and German.

S e t u p L a n g u a g e > E n g l i s h

OM-188 304 Page 22

5-7. Choosing Pulse Programs And Setting Parameters

Choosing Pulse Program: Pulse programs are pre-written and cannot be changed by the user. See Section 6 for program parameters and recommended gas mixtures. Choose program depending on the type and size of wire, and type of shielding gas used. For example, the program shown below is for .045 steel wire using Ar/CO2 gas.

> P r g

0 4 5 S t

Ar / C O 2

A d a p t i v e

P u l s e

Choosing Adaptive Or Non Adaptive: Adaptive: Pulse frequency is automatically regulated to maintain a constant arc length, regardless of changes in wire stickout. Non Adaptive: Constant pulse frequency is maintained, regardless of the arc length. Choose mode which best applies to your application.

Setting Arc Length: Arc length is adjusted with the Output Adjust control. Displayed preset Trim values (0 100) are for reference only. Adjustment normally needed if wire feed speed or type of weld joint is changed. Set arc length that best applies to your application.

OM-188 304 Page 23

5-8. How Manual Pulsed MIG Waveform Components Affect Arc And Burn-Off Rate

OM-188 304 Page 24

SECTION 6 PROGRAMS NOTE

Synergic Information: The manufacturer makes no warranties, express or implied, that welds made using the synergic parameters of this equipment will meet the requirements of the application. The synergic parameters contained in this equipment are intended only to be a general guideline. The choice and use of any synergic setting must be tested as to its suitability for the application.

6-1. Overview Of Programs

Program #
1 2 3 4 5 6 7 8 9 10 11 12

Wire Type
Steel Steel Stainless Stainless 4043AL 4043AL 5356AL 5356AL Nickel Silicon Bronze Metal Core Metal Core

Wire Size
.035 in .045 in .035 in .045 in .035 in .047 in .035 in .047 in .035 in .035 in .045 in .052 in

Shielding Gas
Argon/CO2 Argon/CO2 98% Argon/2% CO2 98% Argon/2% CO2 Argon Argon Argon Argon 75% Argon/25% Helium Argon Argon/CO2 Argon/CO2

IPM: Min
100 80 100 90 140 100 180 140 80 120 100 60

IPM: Max
780 550 780 620 870 730 880 730 780 780 550 450

6-2. Individual Program Information

Program 1 .035 ER70S3 Mild Steel Recommended Gases: Argon/CO2 Gas: Argon/CO2 mixes up to 10% CO2; Argon/O2 mixes up to 5% O2 IPM
100 168 236 304 372 440 508 576 644 712 780

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
288 304 332 353 360 375 385 390 345 398 400

Background Amp
43 54 67 80 84 88 98 101 109 114 121

Freq.
49 93 110 124 155 180 195 208 215 240 260

Pulse Width
1.55 1.61 1.73 1.86 1.96 2.05 2.13 2.21 2.30 2.38 2.48

Starting Amps
451 491 501 529 529 529 529 529 529 529 529

OM-188 304 Page 25

Program 2 .045 ER70S3 Mild Steel Recommended Gases: Argon/CO2 Gas: Argon/CO2 mixes up to 10% CO2; Argon/O2 mixes up to 5% O2 IPM
80 127 174 221 268 315 362 409 456 503 550

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
323 342 370 388 390 400 400 400 400 400 400

Background Amp
48 61 84 95 108 119 139 152 178 219 277

Freq.
56 91 108 134 155 175 183 200 215 230 250

Pulse Width
2.20 2.28 2.38 2.53 2.65 2.73 2.83 2.86 2.93 2.99 3.10

Starting Amps
498 529 529 529 529 529 529 529 529 529 529

Program 3 .035 309L Stainless Steel Recommended Gases: 98% Argon/2% CO2 Alternative Gases: Argon/CO2 mixes up to 10% CO2; Argon/O2 mixes up to 5% O2 IPM
100 168 236 304 372 440 508 576 644 712 780

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
257 266 282 298 315 328 349 362 376 395 400

Background Amp
26 44 70 84 89 95 107 112 118 122 123

Freq.
57 82 91 106 123 135 144 171 180 183 190

Pulse Width
1.62 1.75 1.85 1.97 2.02 2.08 2.19 2.25 2.30 2.33 2.43

Starting Amps
400 430 456 482 503 520 529 529 529 529 529

Program 4 .045 309L Stainless Steel Recommended Gases: Argon/CO2 Gas: Argon/CO2 mixes up to 10% CO2; Argon/O2 mixes up to 5% O2 IPM
95 147 198 250 301 353 404 456 507 559 610

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
295 318 351 359 379 390 400 400 400 400 400

Background Amp
35 54 75 97 100 109 117 133 149 166 175

Freq.
90 105 125 143 160 175 185 200 220 240 260

Pulse Width
1.80 2.00 2.00 2.20 2.40 2.50 2.50 2.65 2.70 2.83 2.80

Starting Amps
448 481 508 529 529 529 529 529 529 529 529

OM-188 304 Page 26

Program 5 .035 Aluminum 4043 Argon IPM

140 213 286 359 432 505 578 651 724 797 870

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
194 196 205 249 272 298 320 340 360 381 400

Background Amp
29 53 80 103 134 150 170 191 214 225 240

Freq.
60 76 98 109 118 125 135 145 155 165 175

Pulse Width
1.10 1.15 1.20 1.35 1.50 1.70 1.90 2.10 2.25 2.40 2.55

Starting Amps
400 501 529 529 529 529 529 529 529 529 529

Program 6 .047 Aluminum 4043 Argon IPM

100 163 226 289 352 415 478 541 604 667 730

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
250 250 271 299 320 351 373 387 400 400 400

Background Amp
39 75 116 163 185 205 225 235 246 257 268

Freq.
50 65 75 105 126 135 148 171 195 212 227

Pulse Width
1.20 1.20 1.30 1.80 2.15 2.45 2.75 3.05 3.35 3.55 3.70

Starting Amps
529 529 529 529 529 529 529 529 529 529 529

Program 7 .035 Aluminum 5356 Argon IPM

180 250 320 390 460 530 600 670 740 810 880

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
221 230 240 250 260 276 291 310 334 354 374

Background Amp
32 43 61 78 87 100 117 139 150 160 170

Freq.
50 71 85 95 105 115 120 130 140 150 160

Pulse Width
1.30 1.35 1.40 1.45 1.55 1.65 1.75 1.85 2.00 2.20 2.30

Starting Amps
484 510 529 529 529 529 529 529 529 529 529

OM-188 304 Page 27

Program 8 .047 Aluminum 5356 Argon IPM

140 199 258 317 376 435 494 553 612 671 730

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
274 280 294 310 323 337 349 359 368 389 400

Background Amp
45 73 95 111 122 141 155 175 192 221 260

Freq.
50 60 70 95 107 116 129 140 156 166 222

Pulse Width
1.30 1.40 1.60 1.85 2.10 2.30 2.50 2.70 2.90 3.10 3.30

Starting Amps
529 529 529 529 529 529 529 529 529 529 529

Program 9 .035 Nickel 75% Argon/25% Helium IPM

80 141 212 283 354 425 496 567 638 709 780

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
221 268 294 327 337 346 368 382 395 400 400

Background Amp
14 36 58 73 89 105 111 122 138 152 169

Freq.
40 60 84 96 114 124 139 149 170 182 167

Pulse Width
1.90 2.10 2.40 2.50 2.65 2.72 2.84 2.90 3.00 3.16 3.55

Starting Amps
458 505 529 529 529 529 529 529 529 529 529

Program 10 .035 Silicon Bronze Argon IPM

120 186 252 318 384 450 516 582 648 714 780

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
238 272 282 301 324 341 363 378 387 400 400

Background Amp
21 43 61 78 95 106 114 128 134 144 144

Freq.
61 71 95 110 129 136 138 143 148 160 194

Pulse Width
1.20 1.30 1.43 1.51 1.50 1.70 1.82 1.88 1.96 2.10 2.16

Starting Amps
503 529 529 529 529 529 529 529 529 529 529

OM-188 304 Page 28

Program 11 .045 Metal Core Recommended Gases: Argon/CO2 Gas: Argon/CO2 mixes up to 20% CO2 IPM
100 145 190 235 280 325 370 415 460 505 550

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
310 330 354 365 370 376 381 385 390 395 400

Background Amp
45 61 70 78 89 100 111 122 138 155 175

Freq.
50 65 90 110 130 150 165 180 190 200 205

Pulse Width
2.30 2.45 2.55 2.65 2.75 2.85 3.00 3.15 3.25 3.35 3.45

Starting Amps
529 529 529 529 529 529 529 529 529 529 529

Program 12 .052 Metal Core Recommended Gases: Argon/CO2 Gas: Argon/CO2 mixes up to 20% CO2 IPM
60 99 138 177 216 255 294 333 372 411 450

Trim
0 10 20 30 40 50 60 70 80 90 100

Peak Amp
360 365 370 374 379 384 387 390 393 396 400

Background Amp
36 70 94 116 133 147 160 174 186 199 210

Freq.
40 50 73 94 112 129 144 159 174 189 204

Pulse Width
2.00 2.10 2.20 2.35 2.50 2.65 2.85 3.00 3.15 3.35 3.50

Starting Amps
529 529 529 529 529 529 529 529 529 529 529

OM-188 304 Page 29

SECTION 7 MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance
Y 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

7-2. Blowing Out Inside Of Unit

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

ST-802 167

OM-188 304 Page 30

7-3. Voltmeter/Ammeter Help Displays

HE.L
V

P0
A

HE.L
V

P5
A

HE.L
V

P1
A

HE.L
V

P6
A

HE.L
V

P2
A

HE.L
V

P7
A

HE.L
V

P3
A

HE.L
V

P8
A

HE.L

P4

10

HE.L

P9

. 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 3-2). 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 3-2). 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-188 304 Page 31

7-4. Error Codes

1 2 Program CRC Error Program Range Error

If either error code appears, reset the display to factory settings as follows:

E R R OR P r o g r a m M e m o r y P r e s s
2

C R C B e R e s e t

Press Parameter Select push button or turn welding power source Off and back On. Change settings and continue.

W i l l P a r m.

S e l e c t

E R R OR P r o g r a m M e m o r y P r e s s R a n g e B e R e s e t

W i l l P a r m.

S e l e c t

7-5. Troubleshooting

Trouble
No weld output; unit completely inoperative.

Remedy
Place line disconnect switch in On position (see Sections 4-6 and 4-7). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 4-6 and 4-7). Check for proper input power connections (see Sections 4-6 and 4-7).

No weld output; meter display On.

Input voltage outside acceptable range of variation (see Section 4-5). Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 3-2). If unit contains optional ground current sensor, excessive current in the ground circuit may have been detected. Have electrician check input power circuit.

Erratic or improper weld output.

Check to make sure correct program is selected for welding wire and shielding gas used. Use proper size and type of weld cable (see Section 4-2). Clean and tighten all weld connections.

No 115 volts ac output at duplex receptacle, Remote 14 receptacle. No 24 volts ac output at Remote 14 receptacle. OM-188 304 Page 32

Reset circuit breaker CB1 (see Section 4-4). Reset circuit breaker CB2 (see Section 4-4).

Notes

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Over 80,000 trained since 1930!

OM-188 304 Page 33

SECTION 8 ELECTRICAL DIAGRAM

197 556-B

Figure 8-1. Circuit Diagram For Welding Power Source (230/460 Volt Models)
OM-188 304 Page 34

206 283-A

Figure 8-2. Circuit Diagram For Welding Power Source (460/575 Volt Models)
OM-188 304 Page 35

2 3 21 20 16 22 17 18 19

68

OM188 304 Page 36

. Hardware is common and

not available unless listed.

8 67 9 14 10 11 25 12 13 24 7 66 65 4 5 6 23 26

15 27

64

63

28

53 54 48 47 46 11 52 50 51 45 44 43 42 33 34 35 36 41 40 39 9 12 37 31 32 59 58 57 56 55 49 29

23

SECTION 9 PARTS LIST

Figure 9-1. Parts Assembly

62

61

60

38

802 166-K

Item No.

Dia. Mkgs.

Part No.

Description Figure 9-1. Parts Assembly

Quantity

. . . 1 . . . . . . . . . . . . . . +175 148 . . . . . . . . . . . . . . . . . . . . . 178 551 . . . . . . . . . . . . . . . . . . . . . 175 256 . . . 2 . . . . . . . . . . . . . . . 195 585 . . . 3 . . . . . . . . . . . . . . . 138 442 . . . 4 . . . . . HD1 . . . . . 182 918 . . . 5 . . . . . . . . . . . . . . . 203 342 . . . 6 . . . . . . . . . . . . . . . 203 341 . . . 7 . . . . . . . . . . . . . . . 181 853 . . . 8 . . . . . D1,2 . . . . . 201 531 . . . 9 . . . . . . . . . . . . . . . 179 276 . . . 10 . . . C5,6 R1 . . . 175 194 . . . 11 . . . . RT1,2 . . . . 173 632 . . . 12 . . . . . . . . . . . . . . . 185 835 . . . 13 . . . . . . . . . . . . . . +183 551 . . . 14 . . . . . . . . . . . . . 604 176 . . . 15 . . . . . . . . . . . . . . . 182 445 . . . 16 . . . . . CB1 . . . . . 089 807 . . . 16 . . . . . CB1 . . . 083 432 . . . 17 . . . . . CB2 . . . . . 083 432 . . . 18 . . . . . . . . . . . . . . . 206 460 . . . 18 . . . . . . . . . . . . . 175 147 . . . 19 . . . . . . . . . . . . . . . 215 980 . . . 20 . . . . . . . . . . . . . . . 183 308 . . . 20 . . . . . . . . . . . . . 183 309 . . . 21 . . . . . . . . . . . . . 217 297 . . . 22 . . . . . . . . . . . . . . . 215 982 . . . 23 . . . . . . . . . . . . . . . 175 138 . . . 24 . . . . . . . . . . . . . . . 148 329 . . . 24 . . . . . . . . . . . . . . . 182 227 . . . 25 . . . . . . . . . . . . . . . 192 853 . . . 26 . . . . . PC1 . . . . . 213 664 . . . 26 . . . . . PC1 . . . . . 215 045 . . . . . . . . . . PLG2 . . . . 131 056 . . . . . . . . . . PLG3 . . . . 130 203 . . . . . . . . . . PLG4 . . . . 115 094 . . . . . . . . . . PLG5 . . . . 115 091 . . . . . . . PLG6, PLG8 . 131 054 . . . . . . . . . . PLG7 . . . . 115 093 . . . . . . . . . . PLG9 . . . . 131 204 . . . . . . . . . . PLG10 . . . . 166 680 . . . 27 . . . . RC10 . . . . 166 679 . . . 28 . . . . W1,2 . . . . 211 493 . . . . . . . . . . . . . . . . . . . . . 173 763 . . . 29 . . . . . . T2 . . . . . . 201 684 . . . 29 . . . . . . T2 . . . . 193 774 . . . . . . . . . . . . . . . . . . . 183 549 . . . 29 . . . . . . T2 . . . . . . 204 256 . . . 31 . . . . . . . . . . . . . . +207 727 . . . 32 . . . . . . . . . . . . . . . 153 403 . . . 33 . . . . . . . . . . . . . . . 177 547 . . . 34 . . . . . CT1 . . . . . 175 199 . . . 35 . . . . . . . . . . . . . . . 025 248 . . . 36 . . . . . C1 . . . . . 186 015 . . . 36 . . . . . C1 . . . . . 193 858 . . . 37 . . . . . C3,4 . . . . . 192 935 . . . 37 . . . . . C3,4 . . . . . 206 756 . . . . . . . . . . . . . . . . . . . . . 193 738 . . . . . . . . . . . . . . . . . . . . . 217 040

. . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, caution falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, current sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, output rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT DIODE, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole . . . . . . . . . . . . . . . . . . . . . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd SP3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . NUT, 1.000NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 2.5A 250VAC . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear w/aux power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, strain relief .709/.984 id x1.375 mtg hole . . . . . . . . . . . . . . . . . . PLATE, ident rear (order by model and serial number) . . . . . . . . . . . . . . . . PLATE, ident rear w/aux power (order by model and serial number) . . . . . COVER, receptacle weatherproof duplex rcpt . . . . . . . . . . . . . . . . . . . . . . . . CABLE, pwr 12ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, caution incorrect voltage (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, caution incorrect voltage (460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg contactor/capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, control (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, control (460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC6, RC8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTACTOR, def prp 40a 8p dual 24vac coil w/interl (230/460 only) . . . STAND-OFF, No. 10-32 x 1.418 (230/460 only) . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control (460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, snap-in nyl .750 ID x 1.000mtg . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, snap-in nyl 1.125mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, insul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, polyp film .34uf 1000VAC (230/460) . . . . . . . . . . . . . . . . . . . . CAPACITOR, polyp film .27uf 1000VAC (460/575) . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 2700uf 450VDC (230/460) . . . . . . . . . . . . . . . . . . . . . . . KIT, capacitor elctlt replacement (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 1800 UF 500 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, nylon m12 thread capacitor mounting . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2 1 1 1 4 2 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 8 1 1 2 1 1 2 1 1 2 1 1 2 1 2 2

OM-188 304 Page 37

Item No.

Dia. Mkgs.

Part No.

Description Figure 9-1. Parts Assembly (continued)

Quantity

. . . 38 . . . . . PC2 . . . . +209 579 . . CIRCUIT CARD, interconnect (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . . PC2 . . . . +208 783 . . CIRCUIT CARD, interconnect (460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG13 . . . . 131 204 . . CONNECTOR & SOCKETS (RC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . PLG14,21 . . 115 093 . . CONNECTOR & SOCKETS (RC2, RC3) . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 39 . . . . . . . . . . . . . . . 175 140 . . BRACKET, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 40 . . . . . . . . . . . . . . . 175 482 . . COIL, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 41 . . . . . . . . . . . . . . . 109 056 . . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 42 . . . . . SR1 . . . . . 179 629 . . KIT DIODE, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 43 . . . . PM1,2 . . . . 208 173 . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 44 . . . . . . Z1 . . . . . . 173 570 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 45 . . . . . . L1 . . . . . . 173 563 . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 46 . . . . . . . . . . . . . . . 207 725 . . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 47 . . . . . . T1 . . . . . . 173 811 . . TRANSFORMER, HF (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 47 . . . . . . T1 . . . . . . 180 952 . . TRANSFORMER, HF (460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 48 . . . . . . . . . . . . . . . 207 467 . . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 49 . . . . . . . . . . . . . . . 175 255 . . INSULATOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 110 386 . . RELAY, 24VAC (460/575 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 50 . . . . . . . . . . . . . . . 173 693 . . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 51 . . . . . . . . . . . . . . . 176 736 . . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 52 . . . . . . . . . . . . . . . 175 132 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 53 . . . . . PC3 . . . . . 213 145 . . CIRCUIT CARD, front panel & display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . PLG11 . . . . 115 091 . . CONNECTOR & SOCKETS (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . PLG17, PLG18 131 054 . . CONNECTOR & SOCKETS (RC4) (RC5) . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 54 . . . . . FM . . . . . 175 084 . . MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 55 . . . . . RC1 . . . . . 189 886 . . RECEPTACLE, w/leads & plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 56 . . . . . . . . . . . . . . . 178 548 . . TERMINAL, connector friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 57 . . . . . C7,8 . . . . . 222 488 . . CAPACITOR, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 58 . . . . . . . . . . . . . . . 187 896 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 59 . . . . . . . . . . . . . . . 129 525 . . RECEPTACLE, twlk insul fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 60 . . . . . . . . . . . . . . . 187 841 . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1 . . . 61 . . . . . . . . . . . . . . . 174 715 . . KNOB, pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 167 633 . . WASHER, shldr nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 188 308 . . WASHER, flat nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . 159 264 . . RING, rtng ext .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 62 . . . . . . . . . . . . . . . 175 855 . . DOOR, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 63 . . . . . . . . . . . . . . . 153 169 . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 64 . . . . . . . . . . . . . . . 176 226 . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 65 . . . . . . S1 . . . . . 128 756 . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 66 . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 67 . . . . . . . . . . . . . . . 199 840 . . BUS BAR, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 68 . . . . . . . . . . . . . . . 190 125 . . LABEL, warning electric shock power cord . . . . . . . . . . . . . . . . . . . . . . . . 1 +When ordering a component originally displaying a precautionary label, the label should also be ordered. Part of 115V Aux Power Option. 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.

OM188 304 Page 38

Effective January 1, 2005 (Equipment with a serial number preface of LF or newer)

Warranty Questions?
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts 3 Years Labor

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.

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1.

Induction Heating Coils and Blankets APT & SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers

Millers True Blue Limited Warranty shall not apply to: 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.

2.

3.

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2.

Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)

3 Years Parts and Labor

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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.
miller_warr 1/05

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Intellitig Maxstar 150 Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems (Non-Integrated) Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Maxstar 85, 140 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.)

3.

1 Year Parts and Labor Unless Specified

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4. 5.

6 Months Batteries 90 Days Parts

MIG Guns/TIG Torches

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

2005 Miller Electric Mfg. Co.

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