Miller Syncrowave 200

|Visit our website at www.MillerWelds.com| |---|



OM-225 389X 2013−02 Processes

TIG (GTAW) Welding


Stick (SMAW) Welding


Description




Arc Welding Power Source

Syncrowave 200

File: TIG (GTAW)


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 the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

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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 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 2009−09

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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.


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

################### SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5............................

################### SECTION 3 − INSTALLATION 11..................................................................

################### SECTION 4 − OPERATION 21....................................................................

################### OPTIONS AND ACCESSORIES WARRANTY

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

som 2011−10

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

########## 1-1. Symbol Usage

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

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE − Indicates statements not related to personal injury.

Indicates special instructions.

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

########## 1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

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

During operation, keep everybody, especially children, away.

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

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!

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

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

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

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

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

Frequently inspect input power cord 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. Disconnect cable for process not in use.

############ SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.

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

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############ HOT PARTS can burn.

Do not touch hot parts bare handed. Allow cooling period before working on equipment.

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

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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 local forced ventilation at the arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator.

Read and understand 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 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 an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under your helmet.

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

Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or 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.

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

Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).

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

Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.

Do not use welder to thaw frozen pipes.

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

Wear 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.

After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

############### FLYING METAL or DIRT can injure eyes.

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

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

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

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

################## ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.

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

Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

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

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result.

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

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.

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

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

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

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

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

############ FALLING EQUIPMENT can injure.

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

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

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

Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.

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

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

############ FLYING SPARKS can injure.

Wear a face shield to protect eyes and face.

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

Sparks can cause fires — keep flammables away.

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

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

############ MOVING PARTS can injure.

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

############ WELDING WIRE can injure.

Do not press gun trigger until instructed to do so.

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

############## BATTERY EXPLOSION can injure.

Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.

############ MOVING PARTS can injure.

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

Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

############ READ INSTRUCTIONS.

Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

Use only genuine replacement parts from the manufacturer.

Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

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

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

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

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

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

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

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################ 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. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

########## 1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, 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, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Officesphone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

########## 1-6. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

################### About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

######## SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

fre_som_2011−10

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.

########## 2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures personnelles.

Indique des instructions spécifiques.

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

########## 2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.

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############ UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.

Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.

Ne pas toucher aux pièces électriques sous tension. Porter des gants isolants et des vêtements de protection secs et sans trous.

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

Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.

Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.

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

D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants,

dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !

Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.

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.

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

Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort.

L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.

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

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

Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place.

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

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

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

############ Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.

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.

############ LES PIÈCES CHAUDES peuvent provoquer des brûlures.

Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement.

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

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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.

À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

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

Lire et comprendre les spécifications de sécurité des matériaux (MSDS) 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 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 approuvé muni de verres filtrants approprié pour protéger visage et yeux 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 lunettes de sécurité avec écrans latéraux même sous votre casque.

Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

| | |---|

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

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent

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

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

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

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

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

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

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

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0 (voir les Normes de Sécurité).

Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).

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

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

En cas de non utilisation, enlever la baguette d’électrode du 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.

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

Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter.

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

Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

| | |---|

############ DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.

Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.

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

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

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

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

################## Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

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

Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.

| | |---|

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

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

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

|| |---|

############ LES BOUTEILLES peuvent exploser si elles sont endommagées.

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

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

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

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

Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état. Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.

Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité.

########## 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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

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

Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

############ LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.

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

Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.

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

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

Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.

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

Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage.

Ne pas obstruer les passages d’air du poste.

############ LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

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

Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

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

| | |---|

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

Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.

############ Les PIÈCES MOBILES peuvent causer des blessures.

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

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

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

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

############## L’EXPLOSION DE LA BATTERIE peut provoquer des blessures.

Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.

############ Les PIÈCES MOBILES peuvent causer des blessures.

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

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

Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

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

| | |---|

############ LIRE LES INSTRUCTIONS.

Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.

N’utiliser que les pièces de rechange recommandées par le constructeur.

Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.

| | |---|

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

Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.

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

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

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

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

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

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

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

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

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

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

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

########## 2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants)

Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.

########## 2-5. Principales normes de sécurité

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Officesphone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060

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

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:

################### En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

| | |---|

##### SECTION 3 − INSTALLATION

########## 3-1. Included with Your Unit

|1 12 ft (3.7 m) Work Cable With Clamp And Quick-Connect
2 WP1712SFDI 150 Amp TIG Torch with 12 ft (3.7 m) Cable And Quick-Connect
3 Electrode Holder and Quick-Connect
4 Gas Hose
5 Gas Regulator
6 Cable/Torch Hanger
7 Foot Pedal Holder
8 8 ft (2.4 m) Primary Cord Without Plug (208/230 Models Only)
9 RFCS-14 Foot Control with 20 ft (6 m) Cable Some assembly is required.


For options and accessories see back of book or contact your distributor.

1

2

3

4

5

8

9

804 464-B

6

7

| |---|

########## 3-2. Selecting A Location

Use lifting eye or lifting forks to move unit.

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

################### Movement

1

Locate unit near correct input power supply.

OR

Position unit so air can circulate. For information about sources of high-frequency see Section 8. For carts and caster kits see back of book or contact your distributor. ! Special installation may be

2

Location And Airflow

3

required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

18 in. (460 mm)

18 in. (460 mm)

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

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

|Front 804 239-B

A

F

E

CB

D|Dimensions|Dimensions| |---|---|---| |Front 804 239-B

A

F

E

CB

D| | | |Front 804 239-B

A

F

E

CB

D|Height|29-3/4 in. (756 mm)| |Front 804 239-B

A

F

E

CB

D|Width|17-1/4 in. (438 mm)| |Front 804 239-B

A

F

E

CB

D|Length|23-1/2 in. (597 mm)| |Front 804 239-B

A

F

E

CB

D|A|19-1/16 in. (484 mm)| |Front 804 239-B

A

F

E

CB

D|B|1 in. (25 mm)| |Front 804 239-B

A

F

E

CB

D|C|14-3/4 in. (375 mm)| |Front 804 239-B

A

F

E

CB

D|D|1 in. (25 mm)| |Front 804 239-B

A

F

E

CB

D|E|1/2 in. (13 mm)| |Front 804 239-B

A

F

E

CB

D|F|4 Holes 7/16 in. dia (11 mm)| |Front 804 239-B

A

F

E

CB

D|Weight|Weight| |Front 804 239-B

A

F

E

CB

D| | | |Front 804 239-B

A

F

E

CB

D|228-1/2 lbs (104 kg) 244-1/2 lbs (111 kg)*|228-1/2 lbs (104 kg) 244-1/2 lbs (111 kg)*| |Front 804 239-B

A

F

E

CB

D|* TIGRunner models|* TIGRunner models|

########## 3-4. Serial Number And Rating Label Location

The serial number and rating information for the power source is located on the front of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

########## 3-5. Specifications

|Model|Mode|Rated Output at 40% Duty Cycle|Rated Input, 60 HZ, Single-Phase|KVA|KW|Welding Amperage Range|Max. OCV| |---|---|---|---|---|---|---|---| |208-230|DC TIG|150 Amps at 16 Volts|208−230 V - 45 A - (2)*|10.2 - (0.50)*|4.3 - (0.3)*|5−200|80| |208-230|DC Stick|150 Amps at 26 Volts|208-230 V - 47 A - (2)*|10.8 - (0.50)*|5.8 - (0.3)*|5−200|80| |208-230|AC TIG**|150 Amps at 16 Volts|208-230 V - 54 A - (2)*|12.3 - (0.50)*|4.5 - (0.3)*|5−200|80| |208-230|AC Stick|150 Amps at 26 Volts|208-230 V - 54 A - (2)*|12.4 - (0.50)*|6 - (0.3)*|5−200|80| |460|DC TIG|150 Amps at 16 Volts|460 V - 22 A - (1)*|10.2 - (0.50)*|4.3 - (0.3)*|5−200|80| |460|DC Stick|150 Amps at 26 Volts|460 V - 25 A - (1)*|10.8 - (0.50)*|5.8 - (0.3)*|5−200|80| |460|AC TIG**|150 Amps at 16 Volts|460 V - 28 A - (1)*|12.3 - (0.50)*|4.5 - (0.3)*|5−200|80|

|460|AC Stick|150 Amps at 26 Volts|460 V - 28 A - (1)*|12.4 - (0.50)*|6 - (0.3)*|5−200|80| |575|DC TIG|150 Amps at 16 Volts|575 V - 19 A - (.5)*|10.2 - (0.50)*|4.3 - (0.3)*|5−200|80| |575|DC Stick|150 Amps at 26 Volts|575 V - 20 A - (.5)*|10.8 - (0.50)*|5.8 - (0.3)*|5−200|80| |575|AC TIG**|150 Amps at 16 Volts|575 V - 22 A - (.5)*|12.3 - (0.50)*|4.5 - (0.3)*|5−200|80| |575|AC Stick|150 Amps at 26 Volts|575 V - 22 A - (.5)*|12.4 - (0.50)*|6 - (0.3)*|5−200|80| |* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|* () While idling.
Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
|

########## 3-6. Duty Cycle Chart

| | |Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating.| |---|---|---| |NOTICE − Exceeding duty cycle can damage unit and void warranty.

40% Duty Cycle at 150 A AC/DC

4 Minutes Welding 6 Minutes Resting

226 798-A|NOTICE − Exceeding duty cycle can damage unit and void warranty.

40% Duty Cycle at 150 A AC/DC

4 Minutes Welding 6 Minutes Resting

226 798-A|NOTICE − Exceeding duty cycle can damage unit and void warranty.

40% Duty Cycle at 150 A AC/DC

4 Minutes Welding 6 Minutes Resting

226 798-A|

########## 3-7. DC Volt-Ampere Curves

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

ssb1.1 10/91 − 226 800-A

DC Stick Max (Max DIG)

DC TIG MaxDC TIG Min

DC Stick Min (Max DIG)

0 50 100 150 200 250 300

AMPS

0

10

20

30

40

50

60

70| |---|

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

ssb1.1 10/91 − 226 799-A

AMPS

0

10

0 50 100 150 200

20

30

40

50

60

70

AC TIG Max

AC Stick Max

AC TIG Min

AC Stick Min| |---|

Notes

For additional welding information and resources, visit: www.MillerWelds.com/resources/improving-your skills

########## 3-9. Weld Output Terminals And Selecting Cable Sizes

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

|! Turn off power before connecting to weld output terminals.

! Do not use worn, damaged, undersized, or poorly spliced cables.

Weld Output Terminals

|Welding Amperes|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*|Weld Cable Size and Total Cable (Copper) Length in Weld Circuit Not Exceeding*| |---|---|---|---|---|---|---|---|---|---| |! Turn off power before connecting to weld output terminals.

! Do not use worn, damaged, undersized, or poorly spliced cables.

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)| |! Turn off power before connecting to weld output terminals.

! Do not use worn, damaged, undersized, or poorly spliced cables.

Weld Output Terminals

|Welding Amperes|10 − 60% Duty Cycle

AWG (mm2)|60 − 100% Duty Cycle

AWG (mm2)|10 − 100% Duty Cycle AWG (mm2)|10 − 100% Duty Cycle AWG (mm2)|10 − 100% Duty Cycle AWG (mm2)|10 − 100% Duty Cycle AWG (mm2)|10 − 100% Duty Cycle AWG (mm2)|10 − 100% Duty Cycle AWG (mm2)| |Electrode

Work

804 234-C|100|4 (20)|4 (20)|4 (20)|3 (30)|2 (35)|1 (50)|1/0 (60)|1/0 (60)| |Electrode

Work

804 234-C|150|3 (30)|3 (30)|2 (35)|1 (50)|1/0 (60)|2/0 (70)|3/0 (95)|3/0 (95)| |Electrode

Work

804 234-C|200|3 (30)|2 (35)|1 (50)|1/0 (60)|2/0 (70)|3/0 (95)|4/0 (120)|4/0 (120)| |Electrode

Work

804 234-C|250|2 (35)|1 (50)|1/0 (60)|2/0 (70)|3/0 (95)|4/0 (120)|2x2/0 (2x70)|2x2/0 (2x70)| |* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use


*For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Ref. S-0007-J 2011−07|

########## 3-10. Remote 14 Receptacle

|AJ

B

K I

C L NH
D M G E F
| |Socket*|Socket Information| |---|---|---|---| |AJ

B

K I

C L NH
D M G E F
| | | |

|AJ

B

K I

C L NH
D M G E F
| |A|15 volts DC.| |AJ

B

K I

C L NH
D M G E F
| |B|Contact closure to A completes 15 volts DC contactor control circuit.| |AJ

B

K I

C L NH
D M G E F
|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
|A|D|Remote control circuit common.| |AJ

B

K I

C L NH
D M G E F
|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
|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.|

########## 3-11. 115 Volts AC Cooler Receptacle And Supplementary Protector CB1

1

2

! Turn Off power before connecting to receptacle or resetting protector.

Provides 115 volts, 15 amps of AC power for coolers. Receptacle is protected from overload by supplementary protector CB1.

RC2 is a designated use receptacle intended for supplying AC power to a Miller-approved cooler.

If CB1 opens, high frequency and output to the 115 volts AC cooler receptacle stop. Press button to reset protector.

804 267-C

########## 3-12. Shielding Gas Connections


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

4

Tools Needed: 3

5

5/8, 1-1/8 in.

! Turn Off power before con-

necting to receptacle.

Fitting has 5/8-18 right-hand threads.

Located on rear of unit.

Gas connection is integrated into the Electrode weld output terminal by means of a flow-through type connector.

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

Connect regulator/flow gauge to gas cylinder.

Connect gas hose to gas in fitting.

Typical flow rate is 20 cfh (cubic feet per hour).

1 2

804 234-C / 804 235-C

########## 3-13. Typical TIG Connections


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

6

5

7

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

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

4

! Turn off power before mak-

ing connections.

A customer supplied remote fingertip control may also be used.

Connect remote control, torch, and work clamp to receptacles as shown.

Chain or secure cylinder to running gear, wall, or other stationary support.

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).

After activating remote control, 0.2 seconds of gas preflow will begin.

################### Preflow Application:

Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. Preflow is preset and is not adjustable.

################### Post Flow 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 (see Section 4-8).

1

3

Tools Needed:

5/8, 1-1/8 in.

########## 3-14. Typical Stick Connections

1

2

! Turn off power before mak-

ing connections.

Connect electrode holder and work clamp to receptacles as shown.

########## 3-15. Electrical Service Guide

Input amperage may be higher than shown in table when Balance control is in an unbalanced position. All values calculated at 40% duty cycle. Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in table. If actual input voltage is outside of this range, damage to unit may occur.

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

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12.

|50/60 Hz Single Phase|50/60 Hz Single Phase|50/60 Hz Single Phase|50/60 Hz Single Phase| |---|---|---|---| |Input Voltage|208-230|460|575| |Input Amperes At Rated Output|54|28|22| |Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1

Time-Delay 2 Normal Operating 3

|60 80|30 40

|25 30

| |Min Input Conductor Size In AWG 4|8|12|14| |Max Recommended Input Conductor Length In Feet (Meters)|147 (45)|249 (76)|256 (78)| |Min Grounding Conductor Size In AWG 4|8|12|14|

Reference: 2011 National Electrical Code (NEC) (including article 630)

########## 3-16. Connecting Input Power In 208-230 Volt Models

1

=GND/PE Earth Ground

5

7

4

6

|L1 L2| | |---|---| |L1 L2| |

1

2

3

Tools Needed:

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

! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

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

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

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

Select type and size of over-current protection using Section 3-15 (fused disconnect switch shown).

Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service.

Input4 2012−05 / 804 234-C / Ref. 803 766-B

‘

########## 3-17. Connecting Input Power In 460/575 Volt Models

| | | |! Disconnect and lockout/tagout input power before installing or moving jumper links.| |---|---|---|---| |Ref. 804 470-B

Check input voltage available at site.

Remove cover and left side panel.

1 Jumper Link Label
2 Jumper Links


Move jumper links to match input voltage.

Install left side panel and cover, or go on to Section B.

Tools Needed:

3/8 in.

1
2
|Ref. 804 470-B

Check input voltage available at site.

Remove cover and left side panel.

1 Jumper Link Label
2 Jumper Links


Move jumper links to match input voltage.

Install left side panel and cover, or go on to Section B.

Tools Needed:

3/8 in.

1
2
|Ref. 804 470-B

Check input voltage available at site.

Remove cover and left side panel.

1 Jumper Link Label
2 Jumper Links


Move jumper links to match input voltage.

Install left side panel and cover, or go on to Section B.

Tools Needed:

3/8 in.

1
2
|Ref. 804 470-B

Check input voltage available at site.

Remove cover and left side panel.

1 Jumper Link Label
2 Jumper Links


Move jumper links to match input voltage.

Install left side panel and cover, or go on to Section B.

Tools Needed:

3/8 in.

1
2
|

############ B. Connecting Input Power In 460/575 Volt Models

| | | |1| |---|---|---|---| |Tools Needed:

804 470-B

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

! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

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

1 Input Power Conductors (Customer Supplied Cord)

Select size and length of conductors using Section 3-15. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Welding Power Source Input Power Connections

2 Strain Relief

Route conductors (cord) through strain relief and tighten screws.

3 Welding Power Source Grounding Terminal
4 Green Or Green/Yellow Grounding Conductor

Connect green or green/yellow grounding conductor to welding power source grounding terminal first.

5 Welding Power Source Line Terminals
6 Input Conductors L1 And L2


Connect input conductors L1 and L2 to welding power source line terminals.

Install panels and wrapper on welding power source.

Disconnect Device Input Power Connections

7 Disconnect Device (switch shown in OFF position)
8 Disconnect Device (Supply) Grounding Terminal

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

9 Disconnect Device Line Terminals

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

10 Overcurrent Protection


Select type and size of overcurrent protection using Section 3-15 (fused disconnect switch shown).

Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.

3/8 in.

2

=GND/PE Earth Ground

1

3

4


4

5 6

|L1 L2| | |---|---| |L1 L2| |

6

7


9

10


8|Tools Needed:

804 470-B

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

! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

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

1 Input Power Conductors (Customer Supplied Cord)

Select size and length of conductors using Section 3-15. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Welding Power Source Input Power Connections

2 Strain Relief

Route conductors (cord) through strain relief and tighten screws.

3 Welding Power Source Grounding Terminal
4 Green Or Green/Yellow Grounding Conductor

Connect green or green/yellow grounding conductor to welding power source grounding terminal first.

5 Welding Power Source Line Terminals
6 Input Conductors L1 And L2


Connect input conductors L1 and L2 to welding power source line terminals.

Install panels and wrapper on welding power source.

Disconnect Device Input Power Connections

7 Disconnect Device (switch shown in OFF position)
8 Disconnect Device (Supply) Grounding Terminal

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

9 Disconnect Device Line Terminals

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

10 Overcurrent Protection


Select type and size of overcurrent protection using Section 3-15 (fused disconnect switch shown).

Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.

3/8 in.

2

=GND/PE Earth Ground

1

3

4


4

5 6

|L1 L2| | |---|---| |L1 L2| |

6

7


9

10


8|Tools Needed:

804 470-B

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

! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

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

1 Input Power Conductors (Customer Supplied Cord)

Select size and length of conductors using Section 3-15. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Welding Power Source Input Power Connections

2 Strain Relief

Route conductors (cord) through strain relief and tighten screws.

3 Welding Power Source Grounding Terminal
4 Green Or Green/Yellow Grounding Conductor

Connect green or green/yellow grounding conductor to welding power source grounding terminal first.

5 Welding Power Source Line Terminals
6 Input Conductors L1 And L2


Connect input conductors L1 and L2 to welding power source line terminals.

Install panels and wrapper on welding power source.

Disconnect Device Input Power Connections

7 Disconnect Device (switch shown in OFF position)
8 Disconnect Device (Supply) Grounding Terminal

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

9 Disconnect Device Line Terminals

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

10 Overcurrent Protection


Select type and size of overcurrent protection using Section 3-15 (fused disconnect switch shown).

Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.

3/8 in.

2

=GND/PE Earth Ground

1

3

4


4

5 6

|L1 L2| | |---|---| |L1 L2| |

6

7


9

10


8|Tools Needed:

804 470-B

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

! Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.

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

1 Input Power Conductors (Customer Supplied Cord)

Select size and length of conductors using Section 3-15. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Welding Power Source Input Power Connections

2 Strain Relief

Route conductors (cord) through strain relief and tighten screws.

3 Welding Power Source Grounding Terminal
4 Green Or Green/Yellow Grounding Conductor

Connect green or green/yellow grounding conductor to welding power source grounding terminal first.

5 Welding Power Source Line Terminals
6 Input Conductors L1 And L2


Connect input conductors L1 and L2 to welding power source line terminals.

Install panels and wrapper on welding power source.

Disconnect Device Input Power Connections

7 Disconnect Device (switch shown in OFF position)
8 Disconnect Device (Supply) Grounding Terminal

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

9 Disconnect Device Line Terminals

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

10 Overcurrent Protection


Select type and size of overcurrent protection using Section 3-15 (fused disconnect switch shown).

Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.

3/8 in.

2

=GND/PE Earth Ground

1

3

4


4

5 6

|L1 L2| | |---|---| |L1 L2| |

6

7


9

10


8|

##### SECTION 4 − OPERATION

########## 4-1. Controls


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

56

0000 0000

| | |---| | |

228 528-A / 242 738-A

1 Output Selector Switch (Polarity)

! 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 Direct Current Electrode Negative (DCEN), AC, or Direct Current Electrode Positive (DCEP) output without changing weld output cable connections.

See Section 4-3.

Use control in conjunction with applicable front panel function switch to set values for that function.

########## 4-2. Ammeter, Voltmeter And Parameter Display


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

12

Displays actual amperage while welding. Meter also displays preset parameters for any of the following units of measure when they are active: amperage, time, percentage or frequency.

Displays output or open-circuit voltage while output is on. Meter also displays preset parameters.

########## 4-3. Amperage/Purge Control


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

3

2

|200 A| |---|

1

See Section 4-12 for Amperage range.

Amperage Control:

Press and release Main Amps push button, and turn Encoder control to set weld amperage. Weld amperage setting is also peak amperage when Pulser function is active (see Section 4-6).

Purge Control:

Press and hold Main Amps push button to activate the gas purge. Purge time can be adjusted from 1 to 50 seconds by turning Encoder control while holding the Amps button. Preset purge time is 0 seconds.

########## 4-4. Process Control


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

1

1 Process Control Press Process button until desired process LED is illuminated:

TIG - When selected, an HF (noncontact) arc starting method is activated. Weld output is not available until a remote control is activated. This method can be used with either AC or DC TIG welding. Make con-

! Weld output terminals are energized when power is on, and Output On LED is lit.

Stick (SMAW) - When Stick is selected, weld output is on, terminals are energized, and output LED is lit. This method can be used with either AC or DC Stick welding. Make con-


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

AC TIG Display

12

BAL 7

3

DC Stick

Display

|DIG| |---|

|30%| |---|

4

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

|Balance Control Examples

|Balance Control Examples

|Balance Control Examples

| |---|---|---| |Setting|Output Waveforms|Arc| | | | | |Typical Starting Point

|BAL| |---|

|7| |---|

|43% Electrode Positive

57% Electrode Negative| | |Limpieza mínima

|BAL| |---|

|10| |---| |40% Electrode Positive

60% Electrode Negative| |

Select desired process, AC TIG or DC Stick (see Section 4-4).

Press Adjust push button to turn Balance/ DIG function and LED on.

If AC TIG is selected, turn encoder control to select appropriate balance value (see Section 4-12). The selected value is displayed on the ammeter, and [BAL] is displayed on the voltmeter.

Balance changes the AC squarewave output. Set control to 7 and adjust as necessary. Begin welding on a sample part. If floating black specs appear in the weld puddle, the balance setting is too high. Turn balance down and repeat steps until puddle is clear.

################### Application:

Joint configuration, set-up, process variables, and oxide thickness may affect setting.

! 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.

AC weld output is preferred for aluminum due to the oxide cleaning action it provides. AC balance controls the amount of cleaning action which should be adjusted according to how heavy or thick the surface oxides are.

Adjust AC balance to the highest setting that provides approximately 0.10 in (2.5 mm) of etching zone along the weld toes, while maintaining a clear, shiny weld puddle.

AC balance should be decreased if a distinct etching zone is not visible near the weld toes, or if the weld puddle appears to have dark, pepper-like spots on the surface.

If DC Stick is selected, turn encoder control to select the appropriate amount of Dig (see Section 4-12). The selected value is displayed on the ammeter, and [DIG] is displayed on the voltmeter.

When set at 0, the DIG current will provide no additional short-circuit amperage at low arc voltage. Increasing the DIG percentage increases the short circuit amperage at a low arc voltage to help start and maintain an arc and prevent the electrode from sticking to the workpiece.

################### Application:

Increase the DIG percentage to reduce or prevent the electrode from sticking to the workpiece.

• For cellulose electrodes (6010, 6011), use

a DIG setting of 50 to 80%.

• For low hydrogen electrodes (7018), use a

DIG setting of 20 to 35%.

• For other electrodes, set DIG high enough

to prevent electrode sticking.

• Setting DIG too high could result in burn thru and unwanted digging due to excessive short circuit current.


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

12 3

PPS 10.0

4

Pulsing is available only while using the TIG process, it cannot be selected if the Stick process (see Section 4-4) is active. Controls can be adjusted while welding.

Press Pulse push button to activate pulser function.

ON - When illuminated, this LED indicates the pulser is on.

Turn Encoder to set pulses per second. See Section 4-12 for Pulse parameters. The selected pulse value is displayed on the ammeter, and [PPS] is displayed on the voltmeter as long as the pulse function is active.

Press Pulse control button to turn pulse function off.

Press Main Amps or Adjust control button to exit pulse control screen and leave pulser activated.

################### Application:

Pulsed TIG welding involves switching the weld output between a high or peak amperage, and a low or background amperage at a controlled rate of pulses per second.

Pulsing the weld output from a higher peak amperage, to a lower background amperage, lowers the average welding amperage, which can reduce heat input and improve weld puddle control.

Set the number of pulses per second based on the application. Pulsing rates of 1 to 2 pps can improve the timing and amount of filler metal that are added to the weld puddle, improving weld bead consistency. Filler metal should be dipped, or added to the weld puddle when the output pulses to the high, or peak amperage.

Fast pulsing rates can improve the bead appearance of welds made without filler, or allow filler to be continuously added to the weld puddle without any dipping action. The pulse rate should be adjusted along with travel speed to obtain desired weld bead appearance.

########## 4-7. Pulser Peak And Background


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

0000 0000

1

| | |---| | |

5

4

| | | |---|---| |Percent (%) Peak Time Control Setting|Pulsed Output Waveforms| | | | |Balanced (50%)|| | | | |---|---|---| | | | |

Peak Amp

Bkg Amp

PPS| |More Time At Peak Amperage

(80%)| | |More Time At Background Amperage

(20%)| |

Push and hold Pulser button and turn on power. Hold button for approximately 7 seconds.

Press Pulse button to cycle parameters (see Section 4-12 for parameter ranges).

PPS (Pulses Per Second or Pulse Frequency) is used to determine appearance of weld bead (See Section 4-6).

PEAK t [PKT] [50%]- The percentage of each pulse cycle that can be spent at the peak amperage level.

BKGND A [BKA] [50%] - (Background Amps) - Use Background Amps to set the low pulse of the weld amperage, which cools the weld puddle and affects overall heat input. Background Amps is set as a percentage of peak amperage.

Turn encoder to select appropriate value for active pulse parameter. Value selected is shown on the ammeter.

Example shows affect changing the Peak Time control has on the pulsed output waveform.

Peak amperage is set using the Main Amps push button control (see Section 4-3), or with a remote control. Peak amperage is the highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage.

################### Application:

Pulsed TIG welding involves switching the weld output between a high or peak amperage, and a low or background amperage at a controlled rate (see Section 4-6). The raised portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level between them (called the background amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding.

Pulsing can also be used for filler material addition technique training.

########## 4-8. Postflow Control


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

3

0000 0000

Postflow time is automatically controlled. Auto-postflow provides a minimum of five seconds of postflow for anything less than 50 amps of weld current, and an additional one second of postflow for each additional ten amps of weld current.

To override auto-postflow and set a specific postflow time, press and hold Process push button while turning on power. Hold button for approximately 7 seconds. Voltmeter will display POST, and ammeter will display AUTO. Turn encoder to set desired time in seconds. Postflow settings effects AC and DC TIG, and is not polarity specific. Press torch trigger or turn off power to save settings.

Application:

Auto-postflow time is optimally set based on weld amperage. This amount of auto-postflow time provides adequate shielding with no manual adjustment. The use of auto-postflow at low amperages avoids excessive postflow times and a waste of shielding gas. See Section 4-12 for postflow parameters.

| | |---| | |

########## 4-9. Selecting Syncro Start Characteristics


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

3

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

0000 0000

1

| | |---| | |

2

To change TIG HF Syncro starting characteristics, turn Off power, place Output Selector switch in desired position, DCEN, DCEP or AC. Each position has three start characteristics options. Push and hold Main Amps button and turn on power. Hold button for approximately 7 seconds.

Meters will display [AC][MED] or [DCEN] [MED], or [DCEP] [MED], depending on position of Output Selector switch

Turn Encoder to step through the three start characteristics choices. Ammeter displays active choice: soft start, medium start, or hot start.

Change polarity (see Section 4-1) to set values for each TIG output. Each setting is polarity specific.

Press torch trigger or turn off power to save settings.

################### Application:

Soft start - use for thin gauge material and small diameter tungstens (.040−1/16 in)

Medium start - factory-set default, used for most welding applications with a 1/16, 3/32 or 1/8 in. tungsten.

Hot start - use for thick materials with a large diameter tungsten (1/8−5/32 in.).

########## 4-10. Timer/Cycle Counter


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

|0000| |---|

|0000| |---|

3

2

1

| | |---| | |

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

|1234| |---|

|5678| |---|

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

|1234|

|---|

|Hour| |---|

|59| |---|

|MINS| |---|

the Process and Pulse buttons, and turn power on.

4 Timer Display

The hours are displayed for five seconds,

and then the minutes are displayed for five seconds. 5 Cycle Display

The cycles are displayed for the next five seconds, and are read as 12,345,678 cycles.

########## 4-11. Software Number/Revision


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

|0000| |---|

|0000| |---|

3

2

1

| | |---| | |

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

|REV.A| |---|

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

|221| |---|

|161| |---|

and hold the Process and Adjust buttons, and turn power on.

4 Software Number Display The software number is displayed for five

seconds. 5 Revision Display The revision is displayed for the next five seconds.

|Parameter|Default|Range And Resolution| |---|---|---| |PROCESS|TIG HF|TIG HF, STICK| |A MAIN / PEAK AC DC|150 A 150 A|5 − 200 Amps 5 − 200 Amps| |PULSER PPS PEAK t BKGND A|Off 10 PPS 50% 50%|ON / OFF 0.1−15 PPS 20 − 80 Percent 5 − 95 Percent|

|POSTFLOW|Auto

Manual:|5 - 50 Amps: 5 Seconds 51 - 200 Amps: Adds 1 Second Per 10 Amps 1 -25 Seconds| |DIG|30%|0 − 100 Percent| |BALANCE|7|1−10| |TIG HF Syncro-Start Settings AC DC|Med Med|Soft/Med/Hot Soft/Med/Hot|

Notes

########## 4-13. Electrode and Amperage Selection Chart For Stick Welding (SMAW)


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

|ELECTRODE|DIAMETER|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE|AMPERAGE

RANGE| |---|---|---|---|---|---|---|---|---|---|---| |ELECTRODE|DIAMETER|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450|50

100

150

200

250

300

350

400

450| |6010 &
6011
|3/32| | | | | | | | | | |6010 &
6011
|1/8| | | | | | | | | | |6010 &
6011
|5/32| | | | | | | | | | |6010 &
6011
|3/16| | | | | | | | | | |6010 &
6011
|7/32| | | | | | | | | | |6010 &
6011
|1/4| | | | | | | | | | |6013|1/16| | | | | | | | | | |6013|5/64| | | | | | | | | | |6013|3/32| | | | | | | | | | |6013|1/8| | | | | | | | | | |6013|5/32| | | | | | | | | | |6013|3/16| | | | | | | | | | |6013|7/32| | | | | | | | | | |6013|1/4| | | | | | | | | | |7014|3/32| | | | | | | | | | |7014|1/8| | | | | | | | | | |7014|5/32| | | | | | | | | | |7014|3/16| | | | | | | | | | |7014|7/32| | | | | | | | | | |7014|1/4| | | | | | | | | | |7018|3/32| | | | | | | | | | |7018|1/8| | | | | | | | | | |7018|5/32| | | | | | | | | | |7018|3/16| | | | | | | | | | |7018|7/32| | | | | | | | | | |7018|1/4| | | | | | | | | | |7024|3/32| | | | | | | | | | |7024|1/8| | | | | | | | | | |7024|5/32| | | | | | | | | | |7024|3/16| | | | | | | | | | |7024|7/32| | | | | | | | | | |7024|1/4| | | | | | | | | |

|Ni-Cl|3/32| | | | | | | | | | |Ni-Cl|1/8| | | | | | | | | | |Ni-Cl|5/32| | | | | | | | | | |Ni-Cl|3/16| | | | | | | | | | |308L|3/32| | | | | | | | | | |308L|1/8| | | | | | | | | | |308L|5/32| | | | | | | | | |

|ELECTRODE

|DC*|AC|POSITION

|PENETRATION|USAGE| |---|---|---|---|---|---| |6010|EP| |ALL|DEEP

|MIN. PREP, ROUGH HIGH SPATTER| |6011|EP| |ALL|DEEP|MIN. PREP, ROUGH HIGH SPATTER| |6013|EP,EN| |ALL|LOW|GENERAL| |7014|EP,EN| |ALL|MED|SMOOTH, EASY, FAST| |7018|EP| |ALL|MED|LOW HYDROGEN, STRONG| |7024|EP,EN| |FLAT HORIZ FILLET|LOW|SMOOTH, EASY, FASTER| |NI-CL|EP| |ALL|LOW|CAST IRON| |308L|EP| |ALL|LOW|STAINLESS| |*EP = ELECTRODE POSITIVE (REVERSE POLARITY)|*EP = ELECTRODE POSITIVE (REVERSE POLARITY)|*EP = ELECTRODE POSITIVE (REVERSE POLARITY)|*EP = ELECTRODE POSITIVE (REVERSE POLARITY)|*EP = ELECTRODE POSITIVE (REVERSE POLARITY)|*EP = ELECTRODE POSITIVE (REVERSE POLARITY)|

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

Ref. S-087 985-A

Notes

##### SECTION 5 − MAINTENANCE AND TROUBLESHOOTING

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

| | | | |! Disconnect power before maintaining.

Maintain more often during severe conditions.| |---|---|---|---|---|

################### 3 Months

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

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

Replace unreadable labels. Replace o-ring in Electrode/Gas Output receptacle if cracked.

Repair or replace cracked weld cable.

Repair or replace cracked gas hose.

################### 6 Months

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

Blow out or vacuum inside.

Or

########## 5-2. Adjusting Spark Gaps

1

2

4

4

Tools Needed:

3/8 in.

! Disconnect and lockout/tagout input power before adjusting spark gaps.

Remove right side panel. 1 Tungsten End Of Point Replace point if tungsten end disappears; do not clean or dress tungsten.

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

3

If adjustment is needed, proceed as follows:

804 236-C /Ref. 803 592-C

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

4 Pressure Point

Apply slight pressure at point until gauge is held firmly in gap. Tighten screws to 12 in/ lbs torque. Adjust other gap.

Reinstall right side panel.

########## 5-3. Voltmeter/Ammeter Help Displays

|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 short in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent.

2 Help1 Display

An SCR overcurrent condition has occurred. Turn power off and back on to correct condition. If problem continues, contact a Factory Authorized Service Agent.

3 Help2 Display


Indicates an open in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Fac-

tory Authorized Service Agent.

4 OVER TEMP XFMR

Indicates the transformer of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-6). Operation will continue when the unit has cooled.

5 Help 4 Display

Indicates an open in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.

6 OVER TEMP RECT


Indicates the rectifier assembly of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-6). Op-

eration will continue when the unit has cooled.

7 Help 9 Display

Indicates a short in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.

8 REL RMT

Indicates Remote Output control is activated. Release Remote Output control to clear help message.

9 POL ERR

Indicates Output Selector switch is not in correct position (see Section 4-1).

10 NOT VALID


Indicates a non-allowable set-up on the front panel.

A

A

V

V

A

A

|0| |---|

|2| |---|

|HELP| |---|

|OVER| |---|

|1| |---|

|TEMP| |---|

V

V

|HELP| |---|

|HELP| |---|

A

A

|4| |---|

|9| |---|

V

V

|OVER| |---|

|REL| |---|

A

A

|TEMP| |---|

|RMT| |---|

7 8

2

5 6

V

|NOT| |---|

10

A

|VALID| |---|

V

V

|HELP| |---|

|HELP| |---|

1

V

|POL| |---|

9

A

|ERR| |---|

3 4

|XFMR| |---|

|RECT| |---|

Toggles Every

Two Seconds}

Toggles Every

Two Seconds}| |---|

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

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

Refer to Section 5-3 for any Help (HLP) message displayed on voltmeter/ammeter.

The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit.| |---|

|Trouble Remedy

|Trouble Remedy

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

|Place machine power switch in On position (see Section 4-1).| |No weld output; unit completely inoperative.

|Place line disconnect switch in On position (see Section 3-16).| |No weld output; unit completely inoperative.

|Check and replace line fuse(s), if necessary (see Section 3-16).| |No weld output; unit completely inoperative.

|Check for proper input power connections (see Section 3-16).| |No weld output; unit on.

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

|Have Factory Authorized Service Agent check unit.| |Unit provides only maximum or minimum weld output.|Make sure Amperage control is in proper position (see Section 4-1).| |Unit provides only maximum or minimum weld output.|Have Factory Authorized Service Agent check unit.| |Erratic or improper weld output.|Use proper size and type of weld cable (see Section 3-9).| |Erratic or improper weld output.|Clean and tighten all weld connections.| |Erratic or improper weld output.|Lay weld cables out straight, do not leave weld cables coiled.| |Erratic or improper weld output.|Check position of Output Selector control (see Section Figure 4-1).| |Erratic or improper weld output.|If using remote control, check position of Amperage Adjustment control (see Section 4-1).| |No control of weld output.|Make sure Amperage control is in proper position (see Section 4-1).| |Lack of high frequency; difficulty in starting GTAW arc.

|Select proper size tungsten (see Section 9-1).| |Lack of high frequency; difficulty in starting GTAW arc.

|Be sure torch 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 5-2).| |Wandering arc − poor control of direction of arc.

|Reduce gas flow rate (see Section 3-13).| |Wandering arc − poor control of direction of arc.

|Select proper size tungsten (see Section 9-1).| |Wandering arc − poor control of direction of arc.

|Properly prepare tungsten (see Section 9-2).| |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 (see Section 4-8).| |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 (see Section 9-2).| |Fan not operating.|Unit equipped with Fan-On-Demand . Fans run only when necessary. Unit equipped with circuitry to protect against overheating.| |No weld output; fan does not run.

|Place line disconnect switch in On position (see Section 3-16).| |No weld output; fan does not run.

|Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-16).| |No weld output; fan does not run.

|Check for proper input power connections (see Section 3-16).| |No weld output; fan on.

|Be sure Output Selector switch is not set between positions (see Section 4-1).| |No weld output; fan on.

|Tighten remote control connection to Remote 14 receptacle (see Section 3-10).| |No weld output; fan on.

|Check remote control (see remote control Owner’s Manual).| |No weld output; fan on.

|Unit overheated. Allow unit to cool (see Section 3-6).| |Fan not operating; weld output available.|Check for and remove anything blocking fan movement.| |Fan not operating; weld output available.|Have Factory Authorized Service Agent check fan motor.|

##### SECTION 6 − PARTS LIST

########## 6-1. Recommended Spare Parts

Dia. Mkgs.

Part No.

Description

Quantity

Recommended Spare Parts

Notes

##### SECTION 7 − ELECTRICAL DIAGRAM

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

############ Figure 7-1. Circuit Diagram For 208−230 Volt Models

231 276-B

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

############ Figure 7-2. Circuit Diagram For 460/575 Volt Models

231 299-B

##### SECTION 8 − HIGH FREQUENCY

########## 8-1. Welding Processes Requiring High Frequency

1

|Work| |---|

TIG

1 High-Frequency Voltage

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

high_freq 5/10 − S-0693

########## 8-2. Installation Showing Possible Sources Of HF Interference

13

50 ft (15 m)

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

11, 12

9 8

7

1

10

3

2

4 5 6

14

###### Best Practices Not Followed

Sources of Direct High-Frequency Radiation

S-0694

########## 8-3. Recommended Installation To Reduce HF Interference

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

3 50 ft (15 m)

50 ft (15 m)

5

1

6

2

8

4

8

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

Ground workpiece if required by codes.

Nonmetal Building

7

9

###### Best Practices Followed

################### Metal Building

8

8

11

10

Ref. S-0695 / Ref. S-0695

Ground metal machine case (clean paint from around hole in case, and use case screw), work output terminal, line disconnect device, input supply, and worktable.

Midpoint between high-frequency source and welding torch.

A circle 50 ft (15 m) from center point in all directions.

Keep cables short and close together.

Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m).

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

Consult the National Electrical Code for specifications.

################### Metal Building Requirements

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 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2011-06

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

########## 9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)

Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference the product packaging to identify the tungsten you are using.

Amperage Range - Gas Type♦ - Polarity Electrode Diameter (DCEN) − Argon

AC − Argon Balance Control @ 65% Electrode Negative (For Use With Aluminum) 2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

Direct Current Electrode Negative (For Use With Mild Or Stainless Steel)

.010 in. (1 mm) Up to 25 Up to 20

.020 in. (1 mm) 15-40 15-35 .040 in. (1 mm) 25-85 20-80 1/16 in. (1.6 mm) 50-160 50-150 3/32 in. (2.4 mm) 130-250 135-235

1/8 in. (3.2 mm) 250-400 225-360 5/32 in. (4.0 mm) 400-500 300-450 3/16 in (4.8 mm) 500-750 400-500 1/4 in. (6.4 mm) 750-1000 600-800

♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour). Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

########## 9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or ACWelding With Inverter Machines

| | |Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust| |---|---|---| |from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.|from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.|from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.|

|Ideal Tungsten Preparation − Stable Arc

2-1/2 Times Electrode Diameter

1 Grinding Wheel

Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.

2 Tungsten Electrode A 2% ceriated tungsten is recommended.
3 Flat

Diameter of this flat determines amperage capacity.

4 Straight Ground Grind lengthwise, not radial.


1

3

4

Causes Wandering Arc

2

Wrong Tungsten

Radial Grinding

Preparation| |---|

####### For additional welding information and resources, visit: www.MillerWelds.com/resources/improving-your skills

#################### TM-216 869 Page 2 Dynasty 350/700, Maxstar 350/700

|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, 2013 (Equipment with a serial number preface of MD 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 delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.

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 2013-01

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

######### 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

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

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

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2013 Miller Electric Mfg. Co. 2013−01

|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

For International Locations Visit www.MillerWelds.com


| |---|