Miller Electric Syncrowave 250




OM-353 122200T October 2000

Processes

TIG (GTAW) Welding


Stick (SMAW) Welding


Description




Arc Welding Power Source

Syncrowave 250

####### 60 Hz, 50 Hz

########### 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 don’t have time to do it any other way.


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

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.



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


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 catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.


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Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business.



Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.| |---|

####### WARNING

This product, when used for welding or cutting, 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.)

The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW

#### TABLE OF CONTENTS

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

Declaration of Conformity For European Community (CE) Products

|NOTE

|This information is provided for units with CE certification (see rating label on unit.)| |---|---|

##### Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA

Declares that the product: Syncrowave 250

conforms to the following Directives and Standards:

Directives Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Electromagnetic Capability Directives: 89/336, 92/31/EEC

Standards Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990 Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1 (April 1995 – Draft revision) Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989 Insulation coordination for equipment within low-voltage systems: Part 1: Principles, requirements and tests: IEC 664-1: 1992 Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995

European Contact: Mr. Luigi Vacchini, Managing Director MILLER Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy

Telephone: 39(02)98290-1 Fax: 39(02)98281-552

dec_con1 10/95

###### SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

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

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

################## Marks a special safety message.

Means “Note”; not safety related.

| | | | |---|---|---|

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.

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

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

########### ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection.

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

Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit.

Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

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

Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

When making input connections, attach proper grounding conductor first – double-check connections. 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 use work clamp or work cable.

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

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

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 after removal of input power on inverters.

Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

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############## FUMES AND GASES can be hazardous.

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

Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator.

Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

########### ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under your helmet.

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

Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

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############# 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.

Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards).

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 and fire hazards.

Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

########### FLYING METAL can injure eyes.

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

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

########### BUILDUP OF GAS can injure or kill.

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

########### HOT PARTS can cause severe burns.

Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.

################# MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away.

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.

Wear approved ear protection if noise level is high.

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########### 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.

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

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

Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder – explosion will result.

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

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use.

Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

########### FIRE OR EXPLOSION hazard.

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

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

########### FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit.

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

########### OVERUSE can cause OVERHEATING

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

############# STATIC (ESD) can damage PC boards.

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

########### MOVING PARTS can cause injury.

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

########### WELDING WIRE can cause injury.

Do not press gun trigger until instructed to do so.

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

########### MOVING PARTS can cause injury.

Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place.

############### H.F. RADIATION can cause interference.

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

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

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

If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained.

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

############### ARC WELDING can cause interference.

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

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. Principal Safety Standards| |---|

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

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.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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 committee’s 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:

################## About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

#### SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION

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|1-1. Signification des symboles| |---|

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

################## Identifie un message de sécurité particulier.

Signifie NOTA ; n’est pas relatif à la sécurité.

| | | | |---|---|---|

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

|1-2. Dangers relatifs au soudage à l’arc| |---|

Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.

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

########### UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous

tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

Ne jamais toucher les pièces électriques sous tension. Porter des gants et des vêtements de protection secs ne comportant pas de trous.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

Ne pas se servir de source électrique àcourant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique àcourant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

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

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

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

Mettre l’appareil hors tension quand on ne l’utilise pas. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps.

Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.

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

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

Porter un harnais de sécurité quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots.

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

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

########### Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique.

Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces.

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########### LES FUMÉES ET LES GAZ peuvent être dangereux.

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

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

A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.

Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

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

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

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

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer

des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé.

Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.

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########### LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincel-

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

Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.

Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

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

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa-

Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.

Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

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

########### DES PARTICULES VOLANTES peuvent blesser les yeux.

Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques vo-

lantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.

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

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

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

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

########### DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

Ne pas toucher des parties chaudes à mains nues Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche.

############## LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez à distance. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

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########### LE BRUIT peut affecter l’ouïe.

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

Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé.

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########### Si des BOUTEILLES sont endommagées, elles pourront exploser.

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

manipuler avec précaution.

Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée – risque d’explosion.

Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille. Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.

|1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance| |---|

########### Risque D’INCENDIE OU D’EXPLOSION.

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

Ne pas installer l’appareil à proximité de produits inflammables

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

########### LA CHUTE DE L’APPAREIL peut blesser.

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

Utiliser un engin d’une capacité appropriée pour soulever l’appareil.

En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

########### L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

Prévoir une période de refroidissement, respecter le cycle opératoire nominal. Réduire le courant ou le cycle opératoire avant de recommancer le soudage.

Ne pas obstruer les passages d’air du poste.

########### LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

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

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

########### DES ORGANES MOBILES peuvent provoquer des blessures.

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

########### LES FILS DE SOUDAGE peuvent provoquer des blessures.

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

Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.

########### DES ORGANES MOBILES peuvent provoquer des blessures.

Rester à l’écart des organes mobiles comme le ventilateur.

Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.

########### LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

Le rayonnement haute frequence peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs.

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

L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation.

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

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

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

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

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

Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.

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

| | |---|

############## LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez à distance.

Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

|1-4. Principales normes de sécurité| |---|

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

|1-5. Information sur les champs électromagnétiques| |---|

Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

################## Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est alors recommandé de respecter les consignes ci–dessus.

#### SECTION 2 – DEFINITIONS

|S-176 254-A

1 1.1 1.2 1.3

3 3.1 3.2 3.3
4 4.1

+


2 2.1 2.2

+

+

5 6




+

2.3

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

1 Electric shock from welding electrode or wiring can kill.

1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating yourself from work and ground.
1.3 Disconnect input plug or power before working on machine.


2 Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust to remove the fumes.
2.3 Use ventilating fan to remove fumes.


3 Welding sparks can cause explosion or fire.


3.1 Keep flammables away from welding. Don’t weld near flammables.
3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it.
3.3 Do not weld on drums or any closed containers.
4 Arc rays can burn eyes and injure skin.

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

5 Become trained and read the instructions before working on the machine or welding.
6 Do not remove or paint over (cover) the label.
| |---|

######### 2-2. Rating Label For CE Products

||S-178 813-A

|1 1

|ISO/IEC 974-1| |---|---|

| | |7A/10.2V 310A/22.4V|7A/10.2V 310A/22.4V|7A/10.2V 310A/22.4V|7A/10.2V 310A/22.4V| |---|---|---|---|---|---|

| | |X|25%|60%|100%| | |U0 = 80V|I2|310A|200A|155A| | |U0 = 80V|U2|22.4V|18V|16.2V| | | |5A/20.2V 310A/32.4V|5A/20.2V 310A/32.4V|5A/20.2V 310A/32.4V|5A/20.2V 310A/32.4V| | | |X|25%|60%

|100%| | |U0 = 80V|I2|310A|200A|155A| | |U0 = 80V|U2|32.4V|28V|26.2V|

|1 50 Hz| | | | |---|---|---|---| |1 50 Hz|U1 = 220|I1max = 117.2A|I1Eff = 59A| |1 50 Hz|U1 = 380|I1max = 72.2A|I1Eff = 36A| |1 50 Hz|U1 = 415|I1max = 63.8A|I1Eff = 32A| |IP 21S|IP 21S|IP 21S|IP 21S|

| |---| | |---|

######### 2-3. Symbols And Definitions

|NOTE

|Some symbols are found only on CE products.| |---|---|

|A Amperes

|Panel–Local|Gas Tungsten Arc Welding (GTAW)|Shielded Metal Arc Welding (SMAW)

| |---|---|---|---| |V Volts

|Do Not Switch While Welding|Arc Force (DIG)

|Spot Timer| |Output

|Circuit Breaker|Remote

|Temperature| |Protective Earth (Ground)

|Alternating Current|High Frequency Start|Input| |Postflow Timer

|Preflow Timer|High Frequency Continuous|High Frequency| |Gas (Supply)

|Gas Input

|Gas Output|Increase/Decrease Of Quantity| |On|Off|Percent

|Direct Current| |Balance Control

|Maximum Cleaning|Maximum Penetration

|Electrode Positive| |Electrode Negative|Crater Time|Meter

|Single-Phase

| |U0 Rated No Load

Voltage (Average)

|U1 Primary Voltage

|U2

Conventional Load Voltage|Line Connection

| |I1 Primary Current

|I2

Rated Welding Current

|X Duty Cycle

|1 1

Single-Phase Combined AC/DC Power Source

| |IP

Degree Of Protection

|I1eff Maximum Effective

Supply Current

|I1max Rated Maximum

Supply Current

|Hz Hertz

| |Electrode|Work

|Thickness Gauge

|Spark Gap

| |S Seconds

| | | |

#### SECTION 3 – INSTALLATION

|Rated Welding Output|PFC**

|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|KVA

|KW

|Amp Range|Max OCV

|IP Rating

| |---|---|---|---|---|---|---|---|---|---|---| |Rated Welding Output|PFC**

|200 V|230 V|460 V|575 V|KVA

|KW

|Amp Range|Max OCV

|IP Rating

| |NEMA Class II (40) – 250 Amperes, 30 Volts AC, 40% Duty Cycle

|No PFC|106 (4.6*)|92 (4*)|46 (2*)|37 (1.6*)|21 (0.89*)|11.4 (0.68*)|5–310 A

|80 V|21 S

| |NEMA Class II (40) – 250 Amperes, 30 Volts AC, 40% Duty Cycle

|With PFC|76|66|33|26|15.2|11.4

|5–310 A

|80 V|21 S

| |*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
**Power Factor Correction
|

|Rated Welding Output|PFC **

|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|Amperes Input at AC Balanced Rated Load Output, 50/60 Hz, Single-Phase|KVA|KW

|Amp Range|Max OCV

|IP Rating

| |---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---| |Rated Welding Output|PFC **

|200 V|220 V|230 V|260 V|380 V|415 V|460 V|520 V|575 V

|KVA|KW

|Amp Range|Max OCV

|IP Rating

| |NEMA Class I (60) – 200 Amperes, 28 Volts AC, 60% Duty Cycle

|No PFC|85 (4.6*)|77 (4.2*)|74 (4*)|65 (3.5*)|45 (2.4*)|41 (2.2*)|37 (2*)|33 (1.8*)|30 (1.6*)|17 (0.9*)|8.3 (0.7*)|5–310 A

|80 V|21 S

| |NEMA Class I (60) – 200 Amperes, 28 Volts AC, 60% Duty Cycle

|With PFC|55 (57*)|64 (51*)|48 (49*)|48 (49*)|37 (30*)|34 (27*)|24 (25*)|48 (49*)|19 (20*)|11 (11*)|8.3 (0.6*)|5–310 A

|80 V|21 S

| |*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|*While idling
Power Factor Correction
|

|The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

ssb1.1 10/91 – SB-116 199 / SB-116 200

A. DC Mode B. AC Mode| |---|

######### 3-3. Duty Cycle And Overheating

| | | |---|---| | | |

40% Duty Cycle At 250 Amperes (60 Hz Models Only)

################## 60% Duty Cycle At 200 Amperes

6 Minutes Welding 4 Minutes Resting

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

If unit overheats, thermostat opens, output stops, light goes on (CE models only), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

Exceeding duty cycle can damage unit and void warranty.

Overheating

########### A

0

15

OR Reduce Duty CycleMinutes

duty1 4/95 / SB-116 198

######### 3-4. Selecting A Location

Movement

1

OR

2

Location And Airflow

6

3

4

18 in (460 mm)

5


18 in (460 mm)

Use lifting eye or lifting forks to move unit.

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

Use rating label to determine input power needs. CE label located on rear panel.

Locate unit near correct input power supply.

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

ST-800 402 / ST-117 264-F

######### 3-5. Dimensions And Weights

|A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|Dimensions

|Dimensions

| |---|---|---| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

| | | |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|Height|30-3/4 in (781 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|Width|19-3/4 in (502 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|Length|27-1/2 in (698 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|A|27 in (686 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|B|26 in (661 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|C|25-1/4 in (642 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|D|1-1/2 in (38 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|E|1-1/8 (29 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|F|17-7/8 (454 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|G|19-1/4 (489 mm)| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|H|1/2 in (13 mm) Dia| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|Weight|Weight| |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

| | | |A

B

C

E D

F Front

G

6 HolesH

ST-154 792-B

|355 lbs (161 kg)|355 lbs (161 kg)|

######### 3-6. Tipping

Be careful when placing or moving unit over uneven surfaces.

######### 3-7. Weld Output Terminals And Selecting Cable Sizes

|ARC WELDING can cause Electromagnetic Interference.

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

|Weld Output Terminals

|Welding Amperes|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding|Total Cable (Copper) Length In Weld Circuit Not Exceeding| |---|---|---|---|---|---|---|---|---|---| |Weld Output Terminals

|Welding Amperes|100 ft (30 m) Or Less|100 ft (30 m) Or Less|150 ft (45 m)|200 ft (60 m)|250 ft (70 m)|300 ft (90 m)|350 ft (105 m)|400 ft (120 m)| |Weld Output Terminals

|Welding Amperes|10 – 60% Duty Cycle|60 – 100% Duty Cycle|10 – 100% Duty Cycle|10 – 100% Duty Cycle|10 – 100% Duty Cycle|10 – 100% Duty Cycle|10 – 100% Duty Cycle|10 – 100% Duty Cycle| |ElectrodeWork

ST-154 795-C|100|4|4|4|3|2|1|1/0|1/0| |ElectrodeWork

ST-154 795-C|150|3|3|2|1|1/0|2/0|3/0|3/0| |ElectrodeWork

ST-154 795-C|200|3|2|1|1/0|2/0|3/0|4/0|4/0| |ElectrodeWork

ST-154 795-C|250|2|1|1/0|2/0|3/0|4/0|2-2/0|2-2/0| |ElectrodeWork

ST-154 795-C|300|1|1/0|2/0|3/0|4/0|2-2/0|2-3/0|2-3/0| |ElectrodeWork

ST-154 795-C|350|1/0|2/0|3/0|4/0|2-2/0|2-3/0|2-3/0|2-4/0| |ElectrodeWork

ST-154 795-C|400|1/0|2/0|3/0|4/0|2-2/0|2-3/0|2-4/0|2-4/0| |ElectrodeWork

ST-154 795-C|500|2/0|3/0|4/0|2-2/0|2-3/0|2-4/0|3-3/0|3-3/0| |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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|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. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E|

######### 3-8. Remote 14 Receptacle

|AJ

B

K I

C L NH
D M G E F


ST-154 795-C

| |Socket*|Socket Information| |---|---|---|---| |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

| | | | |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

| |A|24 volts ac.| |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

| |B|Contact closure to A completes 24 volts ac contactor control circuit.| |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

|A

|C

|Command reference; 0 to +10 volts dc output to remote control.| |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

|A

|D|Remote control circuit common.| |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

|A

|E|0 to +10 volts dc input command signal from remote control.| |AJ

B

K I

C L NH
D M G E F


ST-154 795-C

|A

|K|Chassis common.| |*The remaining sockets are not used.|*The remaining sockets are not used.|*The remaining sockets are not used.|*The remaining sockets are not used.|

######### 3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections

Turn Off power before connecting to receptacle.

Receptacle is protected from overload by circuit breaker CB1 (see Section 5-2).

Fittings have 5/8-18 right-hand threads

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

Typical flow rate is 20 cfh (cubic feet per hour) (9.4 L/min)

5

4

6

| | | |---|---|

| | | | | | |---|---|---|---|---|

1 7

3 2

Ref. ST-154 795-C / Ref. ST-157 858

######### 3-10. Electrical Service Guide

|NOTE

|All values calculated at 60% duty cycle.| |---|---|

|60 Hertz Models|Without Power Factor Correction|Without Power Factor Correction|Without Power Factor Correction|Without Power Factor Correction|With Power Factor Correction|With Power Factor Correction|With Power Factor Correction|With Power Factor Correction| |---|---|---|---|---|---|---|---|---|

|Input Voltage|200|230|460|575|200|230|460|575| |Input Amperes At Rated Output|85|74|37|30|55|48|24|19| |Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes|125|110|60|45|80|70|35|30| |Min Input Conductor Size In AWG/Kcmil|4|6|10|10|8|8|12|14| |Max Recommended Input Conductor Length In Feet (Meters)|173 (53)|158 (48)|291 (89)|455 (139)|86 (26)|114 (35)|186 (58)|189 (48)| |Min Grounding Conductor Size In AWG/Kcmil|6|6|10|10|8|8|12|14| |Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|

|50 Hertz Models|Without Power Factor Correction|Without Power Factor Correction|Without Power Factor Correction|Without Power Factor Correction|Without Power Factor Correction|With Power Factor Correction|With Power Factor Correction|With Power Factor Correction| |---|---|---|---|---|---|---|---|---| |Input Voltage|220|260|380|415|520|220|380|415| |Input Amperes At Rated Output|77|65|45|41|33|64|37|34| |Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes|125|100|70|60|50|90|60|50| |Min Input Conductor Size In AWG/Kcmil|6|6|8|8|10|6|10|10| |Max Recommended Input Conductor Length In Feet (Meters)|145 (44)|202 (62)|291 (89)|347 (106)|372 (113)|145 (44)|291 (89)|347 (106)| |Min Grounding Conductor Size In AWG/Kcmil|6|8|8|10|10|6|8|10| |Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|Reference: 1996 National Electrical Code (NEC) S-0092-J|

######### 3-11. Placing Jumper Links And Connecting Input Power

1

|230 VOLTS

|LL| |---|

460 VOLTS

|LL

| |---|

200 VOLTS

|LL| |---|

S-083 566-C| |---|

|230 VOLTS

|LL| |---|

460 VOLTS

|LL

| |---|

S-010 587-B

|LL

| |---|

575 VOLTS| |---|

|220 VOLTS

|LL| |---|

380 VOLTS

|LL

| |---|

S-131 783-A

|LL

| |---|

415 VOLTS| |---|

|S-047 672-A

260 VOLTS

|LL| |---|

380 VOLTS

|LL| |---|

520 VOLTS

|LL| |---| | |---|

Connect GND/PE Conductor First

L1 (U) L2 (V)

GND/PE Earth Ground

4

Check input voltage available at site.

Check label inside your unit– only one label is on unit.

Only make connections for the voltages shown on the label inside your unit. Do not make connections for any other voltages. If jumper link label is missing from inside unit, check rating label (see Section 3-4) for allowable input voltages.

Move jumper links to match input voltage.

Select size and length using Section 3-10.

Select type and size of overcurrent protection using Section 3-10.

Reinstall side panel.

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

Tools Needed:

3/8 in 3/8, 1/2, 7/16 in

Connect GND/PE Conductor First

ST-117 263-K

#### SECTION 4 – OPERATION

|Ref. ST-117 264-F / Ref. ST-154 795-C

15

14

13

12

11

10

9

87

6

5

4 3

2

1

1 Ammeter See Section 4-3.
2 Voltmeter

See Section 4-3.

3 High Frequency Switch

See Section 4-11.

4 Output (Contactor) Switch

See Section 4-8.

5 Spot Time Switch And Control (Optional)

See Section 4-5.

6 Preflow Time Control (Optional) See Section 4-12. 7 AC Balance Control

See Section 4-6.

8 Crater Time Control And Switch See Section 4-4. 9 Amperage Adjustment Control And

Switch

See Section 4-7.


10 Arc Force (Dig) Switch And Control

See Section 4-9.

11 Postflow Time Control

See Section 4-10.

12 High Temperature Shutdown Light (CE Models Only)

Lights when unit overheats and shuts down (see Section 3-3).

13 Power Switch And Pilot Light Use switch to turn unit and light On and Off. 14 Output Selector Switch See Section 4-2. 15 High Frequency Control

See Section 4-11.








| |---|

######### 4-2. Output Selector Switch

1

1 Output Selector Switch

Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control.

Do not change position of switch while welding or while under load.

Use switch to select (DCEN) Direct Current Electrode Negative, AC, or (DCEP) Direct Current Electrode Positive output without changing weld output cable connections.

Ref. ST-181 675-A

######### 4-3. Meters

|1 Voltmeter

Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to cable resistance, poor connections, etc.

2 Ammeter


Ammeter displays weld amperage output of unit.

1 2

| |---|

######### 4-4. Crater Time Controls

|1 Crater Time Control

Use control to reduce current over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control.

2 Crater Time Switch ON – provides crater time. OFF – provides no crater time.


Place switch in the OFF position for Shielded Metal Arc Welding (SMAW).

Application:

Crater Time should be used while GTAW welding materials that are crack sensitive, and/or the operator wants to eliminate the crater at the end of the weld.

Note: This applies if the operator is using an on/off only type control to start and stop the welding process.

2

1

| |---|

######### 4-5. Spot Time Controls

|1 Spot Time Switch

Place switch in the ON position to turn on spot weld circuitry.

The (GTAW) TIG Spot process is generally used with a direct current electrode negative (DCEN) set-up.

Place switch in the OFF position to turn off spot weld circuitry. Put switch in the OFF position while doing Shielded Metal Arc Welding (SMAW).

2 Spot Time Control


Use control to set time (0–5.7 seconds) for Gas Tungsten Arc (GTAW) spot welds. Spot time begins at arc initiation. If the arc is broken during the spot time cycle, the timer stops but does not reset. When the spot time has ended, weld output stops. Postflow starts when the remote contactor is opened. The spot timer resets after the contactor opens.

Application:

TIG spot welding is used for joining thinner materials that are in close contact, with the fusion method. A good example would be joining coil ends.

1

2


| |---|

######### 4-6. AC Balance Control

|Ref. S-0795-A

1 AC Balance Control Balance Control (AC GTAW):

Control changes the AC output square wave. Rotating the control towards 10 provides deeper penetration. Rotating the control towards 0 provides more cleaning action of the workpiece.

When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action.

Application:

When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only a minimal amount, approximately a 0.10 in (2.5mm) of etched zone along the weld toes is required.

Set control to 7 and adjust as necessary. Joint configuration, set-up, process variables, and oxide thickness may affect setting.

Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the Balance control towards maximum penetration, may help to restabilize the arc.

|Setting|Output Waveforms|Arc| |---|---|---| | | | | |Balanced 3|50% Electrode Positive

50% Electrode Negative| | |10

More Penetration|32% Electrode Positive

68% Electrode Negative| | |0

More Cleaning|55% Electrode Positive

45% Electrode Negative| |

1

| |---|

######### 4-7. Amperage Adjustment Controls

|1 Amperage Adjustment Control

Use control to adjust amperage, and preset amperage on ammeter (see Section 4-3). This control may be adjusted while welding.

For remote amperage control, front panel control setting is the maximum amperage available. For example: If front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A.

For spot welding, use Amperage Adjust control to select from 5–310 amps of peak amperage (see Section 4-5).

2 Amperage Control Switch


Use switch to select way of controlling amperage adjustment.

For front panel control, place switch in the PANEL position.

For remote control, place switch in REMOTE 14 position, and connect remote control device (see Section 3-8).

1

2

| |---|

######### 4-8. Output (Contactor) Control Switch

1

Weld output terminals are energized when Output (Contactor) switch is On and Power is On.

1 Output/Contactor Switch Use switch to select way of controlling unit output. For front panel control, place switch in ON position. When On is selected, HF and gas control are disabled.

For remote control, place switch in REMOTE 14 position, and connect remote control device (see Section 3-8).

######### 4-9. Arc Controls

|1 Arc Control (Dig)For AC And DC SMAW Welding

When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage.

When setting is increased, shortcircuit amperage at low arc voltage increases.

Set at 0 for GTAW welding.

2 Arc Control Switch

Place switch in the ON position to turn on arc control circuitry. When switch is in the OFF position, no additional amperage is available at low arc voltages. Place switch in the OFF position while performing Gas Tungsten Arc Welding (GTAW).

Application:

Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding.

2

1

| |---|

######### 4-10. Postflow Time Control

|1 Postflow Time Control

Use control to set length of time (0–70 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow until after the tungsten and weld puddle has cooled down.

Application:

Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance.

1

| |---|

######### 4-11. High Frequency Controls

|Place High Frequency switch in Off position before using the shielded metal arc welding (SMAW) process.

1 High Frequency Switch

START – (Up position) provides HF for arc starting only. High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTAW process is required.

OFF – provides no HF. Use OFF for SMAW (stick electrode) welding.

CONTINUOUS – (Down position) provides HF continuously throughout the weld.

Application:

HF Continuous is used when the AC GTAW process is required.

2 High Frequency Intensity Control


Use control to change amount of HF energy used to start and maintain the arc. Set as low as practical to prevent interfering with electronic equipment.

1

2| |---|

######### 4-12. Preflow Time Control (Optional)

|1 Preflow Time Control

Use control to set the length of time (0–15 seconds) that gas flows before an arc is started.

Application:

Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

1

| |---|

#### SECTION 5 – MAINTENANCE & TROUBLESHOOTING

######### 5-1. Routine Maintenance

|Disconnect power before maintaining.| |---| |3 Months| |Replace Unreadable Labels

Clean And Tighten Weld Terminals

Repair Or Replace Cracked Weld Cables| |Adjust Spark Gaps

Replace Cracked Parts 14-Pin Cord Gas Hose Torch Cable

| |6 Months| |OR

Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly|

######### 5-2. Circuit Breaker CB1

1

################## CB1

1 Circuit Breaker CB1

If CB1 opens, output to the 115 volts ac duplex receptacle, high frequency, and gas flow stop. Press button to reset breaker.

Ref. ST-154 795-C

######### 5-3. Adjusting Spark Gaps

4

43

| | | | | | | | | | | |---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |

3

1

2

Tools Needed:

Turn Off power before adjusting spark gaps.

Open access door.

Replace point if tungsten end disappears; do not clean or dress tungsten.

Normal spark gap is 0.008 in (0.203 mm).

If adjustment is needed, proceed as follows:

Loosen screws. Place gauge of proper thickness in spark gap.

Apply slight pressure at point until gauge is held firmly in gap. Tighten screws. Adjust other gap.

Close access door.

Ref. ST-154 795-C / Ref. S-0043

######### 5-4. Troubleshooting

| | | |---|---| |Trouble Remedy

|Trouble Remedy

| | | | |No weld output; unit completely inoperative.

|Place line disconnect switch in On position (see Section 3-11).| |No weld output; unit completely inoperative.

|Check and replace line fuse(s), if necessary (see Section 3-11).| |No weld output; unit completely inoperative.

|Check for proper input power connections (see Section 3-11).| |No weld output; unit completely inoperative.

|Check for proper jumper link position (see Section 3-11).| |No weld output; unit on.

|If using remote control, place Output switch in Remote 14 position, and make sure remote control is connected to Remote 14 receptacle. If remote is not being used, place Output (Contactor) switch in On position.| |No weld output; unit on.

|Check, repair, or replace remote control.| |No weld output; unit on.

|Unit overheated. Allow unit to cool with fan On (see Section 3-3).| |No weld output; unit on.

|Have Factory Authorized Service Agent check control board PC1.|

|Trouble Remedy|Trouble Remedy| |---|---| | | | |Fan not operating. NOTE: fan only runs when cooling is necessary.

|Check and remove anything blocking fan movement.| |Fan not operating. NOTE: fan only runs when cooling is necessary.

|Have Factory Authorized Service Agent check fan motor.| |Unit provides only maximum or minimum weld output.|Have Factory Authorized Service Agent check control board PC1.| |Weld output always above or always below set value.|Have Factory Authorized Service Agent check control board PC1 and hall device HD1.| |Erratic or improper weld output.

|Use proper size and type of weld cable (see Section 3-7).| |Erratic or improper weld output.

|Clean and tighten all weld connections.| |Erratic or improper weld output.

|Check position of Output Selector switch (see Section Figure 4-1).| |Erratic or improper weld output.

|Have Factory Authorized Service Agent check control board PC1 and hall device HD1.| |No AC Balance control.|Have Factory Authorized Service Agent check AC Balance control and control board PC1.| |No control of weld output.

|If using remote control, place Output switch in Remote 14 position, and make sure remote control is connected to Remote 14 receptacle. If remote is not being used, place Output switch in On position.| |No control of weld output.

|Have Factory Authorized Service Agent check Amp Adjust control and control board PC1.| |No high frequency, no gas flow, and no 115 volts ac output from duplex receptacle.|Reset circuit breaker CB1 (see Section 5-2).| |Lack of high frequency; difficulty in starting GTAW arc.

|Select proper size tungsten.|

|Lack of high frequency; difficulty in starting GTAW arc.

|Check High Frequency control setting (see Figure 4-1).| |Lack of high frequency; difficulty in starting GTAW arc.

|Be sure electrode holder cable is not close to any grounded metal.| |Lack of high frequency; difficulty in starting GTAW arc.

|Check cables and torch for cracked insulation or bad connections. Repair or replace.| |Lack of high frequency; difficulty in starting GTAW arc.

|Check spark gaps (see Section 5-3).| |Wandering arc – poor control of direction of arc.

|Reduce gas flow rate.| |Wandering arc – poor control of direction of arc.

|Select proper size tungsten.| |Wandering arc – poor control of direction of arc.

|Properly prepare tungsten.| |Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

|Shield weld zone from drafts.| |Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

|Increase postflow time.| |Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

|Check and tighten all gas fittings.| |Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

|Properly prepare tungsten.| |Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

|Check for water in torch, and repair torch if necessary. See torch Owner’s Manual.|

######### 5-5. Circuit Diagram

| | | |---|---| | | |

| | | |---|---| | | |

| | | | |---|---|---| | | | |

| | | |---|---| | | | | | |

SC-188 161-A

#### SECTION 6 – HIGH FREQUENCY (HF)

######### 6-1. Welding Processes Using HF

2 1

1

Work Work

Gas Tungsten Arc Welding (GTAW)

Submerged Arc Welding (SAW)

######### 6-2. Sources Of HF Radiation From Incorrect Installation

################## Weld Zone

11, 12

50 ft (15 m)

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

SAW – helps arc reach workpiece through flux granules.

high_freq1 7/95 – S-0693

13

9 8

7

1

10

3

2

4 5 6

14

S-0694 Sources Of Direct HF Radiation

######### 6-3. Correct Installation

50 ft (15 m)

################## Weld Zone

50 ft (15 m)

4

6

1

5

2

7

3

7

Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Wire

Ground Workpiece If Required By Codes

8

Nonmetal Building

7

7

10

Metal Building

9

Ref. S-0695 / Ref. S-0695

Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.

A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions.

Locate HF source at least 50 ft (15 m) away from power and phone lines.

Consult the National Electrical Code for specifications.

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

Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh.

#### SECTION 7 – PARTS LIST

17–Fig.7–4

18

19

20

16

30

13

31

14

10

7–Fig.7–5

5 6

15

24

23

25

4

3

2–Fig.7–3

28

21

22

29–Fig.7–2

1

Figure 7-1. Main Assembly ST-120 135-RHardware is common and not available unless listed.

Replace Coils at Factory or Authorized Factory Service Station

Item No.

Dia. Mkgs.

Part No.

Description Quantity

Figure 7-1. Main Assembly

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

Hardware is common and not available unless listed.

2

1

3

29

1

Fig 7-6

21

20

23

2224

4 5 6

7

4

8

9

|12
13
| | |---|---| |12
13
| |

Includes Item 26

17

14

15 16

19

18

########### Figure 7-2. Panel, Front w/Components

ST-120 088-G

########### Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 29)

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

Dia. Mkgs.

Part No.

Item No.

Description Quantity

181 106

Hardware is common and not available unless listed.

3

2

4

2

1

5

| | | | | | |---|---|---|---|---| | | | | | | | | | | | |

| | | | | | |---|---|---|---|---| | | | | | | | | | | | |

ST-120 205-A6

5

Figure 7-3. Rectifier, Si Diode

Item No.

Dia. Mkgs.

Part No.

Description Quantity

Figure 7-4. Panel, Rear w/Components (Fig 7-1 Item 17)

23

Hardware is common and not available unless listed.

1

4

5

6

ST-120 089-F

########### Figure 7-4. Panel, Rear w/Components

########### Figure 7-5. Panel, Mtg Components (Fig 7-1 Item 7)

Hardware is common and not available unless listed.

1

2

11

3

10

3

6

4

5

6

9

78

ST-120 090-F

########### Figure 7-5. Panel, Mtg Components

Hardware is common and not available unless listed.

2

3

1

4

23

22

21

20

5

6

10

14

11

13

12

15

16

17

18

19

########### Figure 7-6. Control Panel, Lower Front

ST-120 003-P

########### Figure 7-6. Control Panel, Lower Front (Fig 7-2 Item 18)

*020 603 POINT, spark gap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 131 203 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Notes

| |

|---|

| | |---|

|Warranty Questions?

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




Your distributor also gives you ...

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

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

Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer)

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

LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. 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.

Miller’s True Blue Limited Warranty shall not apply to:

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 Miller’s 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 customer’s risk and expense. Miller’s 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 7/00

Owner’s Record

Please complete and retain with your personal records.

############ Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

######## Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate 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

Contact the Delivering Carrier for:

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

File a claim for loss or damage during shipment.

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00

|Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters–USA 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



| |---|