OM-353

November 2000

122200U

Processes
TIG (GTAW) Welding Stick (SMAW) Welding

Description

Arc Welding Power Source

Syncrowave 250
R

60 Hz, 50 Hz

Visit our website at

www.MillerWelds.com

From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you Miller is the first welding figure out what the problem is. The parts list equipment manufacturer in will then help you to decide which exact part the U.S.A. to be registered to the ISO 9001 Quality System you may need to fix the problem. Warranty and Standard. service information for your particular model are also provided.

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

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

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

TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . 3-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11. Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Crater Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Spot Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. AC Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Amperage Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Output (Contactor) Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. High Frequency Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Preflow Time Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 – HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Welding Processes Using HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Sources Of HF Radiation From Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 3 4 5 5 5 7 8 8 9 9 10 11 12 12 12 13 14 14 15 15 16 16 17 18 19 19 20 20 21 21 22 23 23 24 24 25 25 26 26 26 27 27 29 30 30 30 31 32

WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

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

Declaration of Conformity For European Community (CE) Products
NOTE
Manufacturer’s Name: Manufacturer’s Address: This information is provided for units with CE certification (see rating label on unit.)

Miller Electric Mfg. Co.
1635 W. Spencer Street Appleton, WI 54914 USA

Declares that the product:

Syncrowave 250
Directives Low Voltage Directive: 73/23/EEC

conforms to the following Directives and Standards:

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Electromagnetic Capability Directives: 89/336, 92/31/EEC Standards Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990 Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1 (April 1995 – Draft revision) Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989 Insulation coordination for equipment within low-voltage systems: Part 1: Principles, requirements and tests: IEC 664-1: 1992 Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995

European Contact:

Mr. Luigi Vacchini, Managing Director MILLER Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy 39(02)98290-1 39(02)98281-552

Telephone: Fax:
dec_con1 10/95

watch out. D When making input connections. D Use only well-maintained equipment. coatings. away. cleaners. and if necessary. D If inside. D Keep your head out of the fumes. Breathing these fumes and gases can be hazardous to your health. D Turn Off inverter. D If AC output is required. state. D Do not use worn. and all metal parts touching the welding wire are electrically live.READ BEFORE USING som _nd_4/98 1-1. unless the coating is removed from the weld area. if movement is confined. or poorly spliced cables. Y During operation. ground. D Do not drape cables over your body. D Frequently inspect input power cord for damage or bare wiring – replace cord immediately if damaged – bare wiring can kill. and local codes. D Keep all panels and covers securely in place. and repair this unit. Welding produces fumes and gases. ELECTRIC SHOCK can kill. lead. D Do not weld in locations near degreasing. while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. Repair or replace damaged parts at once. wire reel. Lockout/tagout input power according to OSHA 29 CFR 1910. and follow the related instructions to avoid the hazard. Be sure the breathing air is safe. Consult symbols and related instructions below for necessary actions to avoid the hazards. D Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. OM-353 Page 1 .147 (see Safety Standards). consumables. ground it directly with a separate cable. or while wearing an air-supplied respirator. D Work in a confined space only if it is well ventilated. not safety related. the area is well ventilated. maintain. or another electrode from a different machine. D Do not touch electrode if you are in contact with the work. and discharge input capacitors according to instructions in Maintenance Section before touching any parts. Y Marks a special safety message. FUMES AND GASES can be hazardous. drive roll housing. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. keep everybody. Incorrectly installed or improperly grounded equipment is a hazard. Do not breathe the fumes. The electrode and work circuit is electrically live whenever the output is on. disconnect input power. D Do not weld on coated metals. especially children. Read and follow all Safety Standards. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not connect more than one electrode or work cable to any single weld output terminal. . D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Do not use AC output in damp areas. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. cleaning. Touching live electrical parts can cause fatal shocks or severe burns. D Wear dry. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. undersized. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. use remote output control if present on unit. D If ventilation is poor. D Turn off all equipment when not in use. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. or if there is a danger of falling. or cadmium plated steel. and HOT PARTS hazards. Always have a trained watchperson nearby. the wire. attach proper grounding conductor first – double-check connections. operate. and degreasers.SECTION 1 – SAFETY PRECAUTIONS . or spraying operations. hole-free insulating gloves and body protection. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Y Only qualified persons should install. D Disconnect input power or stop engine before installing or servicing this equipment. 1-2. When you see the symbol. Means “Note”. Maintain unit according to manual. D If earth grounding of the workpiece is required. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. D Use AC output ONLY if required for the welding process. D Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals. ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. D Do not touch live electrical parts. D Wear a safety harness if working above floor level. D Properly install and ground this equipment according to its Owner’s Manual and national. use an approved air-supplied respirator. damaged. MOVING PARTS. such as galvanized. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding.

overheating. D Read and follow instructions on compressed gas cylinders.1 listed in Safety Standards). sparks.1 and Z87. open flames. D Keep protective cap in place over valve except when cylinder is in use or connected for use. HOT PARTS can cause severe burns. D Turn face away from valve outlet when opening cylinder valve. Accidental contact of electrode to metal objects can cause sparks. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Welding. Since gas cylinders are normally part of the welding process. WELDING can cause fire or explosion. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49. bulkhead. NOISE can damage hearing. D Wearers should consult their doctor before going near arc welding. possibly unknown paths and causing electric shock and fire hazards. D Wear oil-free protective garments such as leather gloves. flame-resistant material (leather and wool) and foot protection. heavy shirt. or pipes. drums. maintain them and associated parts in good condition. and keep a fire extinguisher nearby. Sparks fly off from the weld. D Allow cooling period before working on gun or torch. MAGNETIC FIELDS can affect pacemakers. can cause them to blow up. D Wear protective clothing made from durable. or pipes. warn others not to watch the arc. Noise from some processes or equipment can damage hearing. chipping. such as a butane lighter or matches. D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long. gouging. hoses. D Never allow a welding electrode to touch any cylinder. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. be sure to treat them carefully. D Do not use welder to thaw frozen pipes. cuffless trousers. D Do not touch hot parts bare handed. D Shut off shielding gas supply when not in use. D Pacemaker wearers keep away. a cylinder can explode. D Wear approved ear protection if noise level is high. mechanical shocks. If this is not possible. D Always ventilate confined spaces or use approved air-supplied respirator. D Remove any combustibles.1 (see Safety Standards). The flying sparks. and grinding cause sparks and flying metal. and fittings designed for the specific application. D Use only correct shielding gas cylinders. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. drums. such as tanks. high shoes. D Keep cylinders away from any welding or other electrical circuits. D Wear approved safety glasses with side shields under your helmet. BUILDUP OF GAS can injure or kill. tightly cover them with approved covers. D Be aware that welding on a ceiling. associated equipment. FLYING METAL can injure eyes. and arcs. D Remove all flammables within 35 ft (10. explosion. and a cap. D Do not weld where flying sparks can strike flammable material.7 m) of the welding arc. slag. Shielding gas cylinders contain gas under high pressure. hot workpiece. from your person before doing any welding. D Wear approved safety glasses with side shields even under your welding helmet. and CGA publication P-1 listed in Safety Standards. they can throw off slag. D Never weld on a pressurized cylinder – explosion will result. OM-353 Page 2 . unless they are properly prepared according to AWS F4. and hot equipment can cause fires and burns. As welds cool. or fire. or spot welding operations. If damaged. or partition can cause fire on the hidden side. D Never drape a welding torch over a gas cylinder. wire brushing. D Watch for fire. D Use protective screens or barriers to protect others from flash and glare. D Protect compressed gas cylinders from excessive heat. floor. D Do not weld on closed containers such as tanks. CYLINDERS can explode if damaged. regulators. Welding on closed containers.ARC RAYS can burn eyes and skin. Check and be sure the area is safe before doing any welding. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Sparks can fly off from the welding arc. D Protect yourself and others from flying sparks and hot metal.

Suite 501. keep weld cables as short as possible. from National Fire Protection Association.F. Miami. H.W. 550 N. Standards Sales. Government Printing Office.2. 550 N. D Do not block or filter airflow to unit. close together. from American Welding Society. using line filters. rated.C. ANSI Standard Z49. Canada M9W 1R3. from National Fire Protection Association. VA 22202. D Do not install or place unit on. D Do not point gun toward any part of the body. D Use proper static-proof bags and boxes to store. 1430 Broadway. New York. ANSI Standard Z87. Additional Symbols For Installation. Have the installation regularly checked and maintained. OM-353 Page 3 . panels. Washington. CSA Standard W117. American Welding Society Standard AWS F4. or shielding the work area. D High-frequency (H. Operation. such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Code for Safety in Welding and Cutting. D Keep away from moving parts. FALLING UNIT can cause injury. CGA Pamphlet P-1.W. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances. MA 02269. LeJeune Rd. Ontario.S. STATIC (ESD) can damage PC boards. D Keep all doors. be sure forks are long enough to extend beyond opposite side of unit. D Use lifting eye to lift unit only.1. and down low. D Reduce current or reduce duty cycle before starting to weld again. To reduce possible interference. Be sure this welding machine is installed and grounded according to this manual. NFPA Standard 51B. keep spark gaps at correct setting. D D D D OVERUSE can cause OVERHEATING D Allow cooling period. D If using lift forks to move unit. or ship PC boards. And Maintenance FIRE OR EXPLOSION hazard. D Be sure all equipment in the welding area is electromagnetically compatible. D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. computers. Miami FL 33126 Safety and Health Standards. follow rated duty cycle. D Do not press gun trigger until instructed to do so. from Superintendent of Documents. If interference still occurs. Safe Practices For Occupation And Educational Eye And Face Protection. other people.1. MOVING PARTS can cause injury. from Canadian Standards Association. Safe Handling of Compressed Gases in Cylinders. from American Welding Society. gas cylinders. D D 1-4. D. and use grounding and shielding to minimize the possibility of interference. and protected to handle this unit. Arlington. using shielded cables.1. Keep high-frequency source doors and panels tightly shut. MOVING PARTS can cause injury. or any metal when threading welding wire. D Do not install unit near flammables. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. ARC WELDING can cause interference. D Do not overload building wiring – be sure power supply system is properly sized.) can interfere with radio navigation.1-3. safety services. NY 10018. D Keep away from moving parts such as fans. OSHA 29 CFR 1910. If notified by the FCC about interference. Rexdale. Quincy. D Keep away from pinch points such as drive rolls. MA 02269. stop using the equipment at once. or near combustible surfaces. U. D Put on grounded wrist strap BEFORE handling boards or parts.F. Cutting And Welding Processes. NFPA Standard 70. 178 Rexdale Boulevard. Batterymarch Park. D Use equipment of adequate capacity to lift and support unit. D Have only qualified persons familiar with electronic equipment perform this installation. covers. or any other accessories. the user must take extra measures such as moving the welding machine. D D WELDING WIRE can cause injury. 20402. RADIATION can cause interference. FL 33126 National Electrical Code. and communications equipment. from American National Standards Institute. Quincy. over. move. 1235 Jefferson Davis Highway. Principal Safety Standards Safety in Welding and Cutting. LeJeune Rd. NOT running gear. and guards closed and securely in place. from Compressed Gas Association. Batterymarch Park.

as it flows through welding cables. Keep cables close together by twisting or taping them. a special blue ribbon committee of the National Research Council concluded that: “The body of evidence. 4.1-5. Connect work clamp to workpiece as close to the weld as possible. To reduce magnetic fields in the workplace. About Pacemakers: Pacemaker wearers consult your doctor first.” However. Until the final conclusions of the research are reached. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current. will cause electromagnetic fields. However. If cleared by your doctor. after examining more than 500 studies spanning 17 years of research. then following the above procedures is recommended. you may wish to minimize your exposure to electromagnetic fields when welding or cutting. 2. Arrange cables to one side and away from the operator. in the committee’s judgment. has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. 5. use the following procedures: 1. 3. Keep welding power source and cables as far away from operator as practical. studies are still going forth and evidence continues to be examined. OM-353 Page 4 . Do not coil or drape cables around your body. There has been and still is some concern about such fields.

D Si la pièce soudée doit être mise à la terre. le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. la terre ou une électrode provenant d’une autre machine. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail. à la réparation ou à l’entretien de l’appareil. le faire directement avec un câble distinct. Leur inhalation peut être dangereux pour votre santé. D Porter un harnais de sécurité quand on travaille en hauteur. . D D D D D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation. D Eloigner votre tête des fumées. D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution. Réparer ou remplacer sur-lechamp les pièces endommagées. Le soudage génère des fumées et des gaz. soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. endommagés. l’utilisation. D Ne pas enrouler les câbles autour du corps. plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure. Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES. le dévidoir. LES FUMÉES ET LES GAZ peuvent être dangereux. D D D Ne pas se servir de source électrique àcourant électrique dans les zones humides. provinciaux et municipaux. le fil. Si la ventilation est insuffisante. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. les nettoyants et les dégraisseurs. utiliser un respirateur à alimentation d’air homologué. tenir toute personne à l’écart et plus particulièrement les enfants. D Ne pas utiliser des câbles usés. D Ne pas toucher l’électrode quand on est en contact avec la pièce. l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Ne pas respirer les fumées. en portant un respirateur à alimentation d’air. aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. UN CHOC ÉLECTRIQUE peut tuer. Dangers relatifs au soudage à l’arc Y Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Se servir d’une source électrique àcourant électrique UNIQUEMENT si le procédé de soudage le demande. Veuillez lire et respecter toutes ces normes de sécurité. D 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. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. Des matériels mal installés ou mal mis à la terre présentent un danger. de nettoyage ou de pulvérisation. D Maintenir solidement en place tous les panneaux et capots. D En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Y Identifie un message de sécurité particulier. Y L’installation. les revêtements. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Lorsque vous voyez un symbole. D D OM-353 Page 5 . S’assurer que l’air de respiration ne présente aucun danger. dans les endroits confinés ou là où on risque de tomber. D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. n’est pas relatif à la sécurité. D N’utiliser qu’un matériel en bon état. Y Au cours de l’utilisation. de grosseur insuffisante ou mal épissés. En soudage semi-automatique ou automatique. débrancher le courant électrique. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910. les consommables. et si nécessaire. D Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux. Signifie NOTA . tels que l’acier galvanisé. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage. ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.147 (voir normes de sécurité). Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux. 1-2. le plus près possible de la soudure. que l’endroit soit bien ventilé. D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre. Demander toujours à un surveillant dûment formé de se tenir à proximité. Ne pas souder des métaux munis d’un revêtement. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. se servir de la fonction de télécommande si l’appareil en est équipé. D Arrêter les convertisseurs. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. D Ne jamais toucher les pièces électriques sous tension. Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire. D Porter des gants et des vêtements de protection secs ne comportant pas de trous. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. D Mettre l’appareil hors tension quand on ne l’utilise pas. A l’intérieur.SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Entretenir l’appareil conformément à ce manuel.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. Fermer l’alimentation du gaz protecteur en cas de non utilisation. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs. D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie. Si des BOUTEILLES sont endommagées. une explosion. Des étincelles sont projetées pendant le soudage. de gougeage ou de soudage par points. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. un surchauffement ou un incendie. D Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Avant de commencer le soudage. enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. du laitier. D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de l’éblouissement. elles risquent de projeter du laitier. des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. elles pourront exploser. les maintenir ainsi que les éléments associés en bon état. elle peut exploser. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc. 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. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. Si une bouteille est endommagée. des chaussures hautes et un couvre chef. tambours ou des conduites peut provoquer leur éclatement. D Lire et suivre les instructions concernant les bouteilles de gaz comprimé. Pendant la période de refroidissement des soudures. D Ne pas toucher des parties chaudes à mains nues D Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. D Ne jamais souder une bouteille pressurisée – risque d’explosion. D D D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49. LE SOUDAGE peut provoquer un incendie ou une explosion. D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. D Déplacer toutes les substances inflammables à une distance de 10. D Avant de souder. des étincelles et des arcs. OM-353 Page 6 . résistant au feu (cuir ou laine) et une protection des pieds. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Maintenir le chapeau de protection sur la soupape. tambours. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage. des chocs mécaniques. des flammes ouvertes. D Le soudage effectué sur un plafond. restez à distance. et le meulage génèrent des étincelles et des particules métalliques volantes. La projection d’étincelles. paroi ou séparation peut déclencher un incendie de l’autre côté. tuyaux et raccords convenables pour cette application spécifique. D Porter des vêtements de protection constitué dans une matière durable. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. plancher. D Le soudage. ou conduites. D Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir. D Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille. D Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé.1 (voir les normes de sécurité). les manipuler avec précaution. retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. LE BRUIT peut affecter l’ouïe. le passage de la pièce à la brosse en fil de fer. Le bruit des processus et des équipements peut affecter l’ouïe. D En cas de non utilisation. une chemise en matériau lourd. D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive. D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. à moins qu’ils n’aient été préparés correctement conformément à AWS F4. les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité. D D Porteurs de stimulateur cardiaque. D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles. D 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. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression.1 et Z87.1 énuméré dans les normes de sécurité). D Utiliser seulement des bouteilles de gaz protecteur. demander aux autres personnes de ne pas regarder l’arc.7 m de l’arc de soudage. régulateurs. Des étincelles peuvent être projetées de l’arc de soudure. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. sauf en cas d’utilisation ou de branchement de la bouteille. l’écaillement. des pantalons sans revers. Le soudage effectué sur des conteneurs fermés tels que des réservoirs. vérifier et s’assurer que l’endroit ne présente pas de danger. DES PARTICULES VOLANTES peuvent blesser les yeux.

D Porteurs de stimulateur cardiaque. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. Effectuer régulièrement le contrôle et l’entretien de l’installation. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. LE SOUDAGE À L’ARC risque de provoquer des interférences. Si le FCC signale des interférences. d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. D Prévoir une période de refroidissement. En cas d’interférences après avoir pris les mesures précédentes. D Rester à l’écart des organes mobiles comme le ventilateur. l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. Pour réduire la possibilité d’interférence. déplacer ou expédier des cartes de circuits imprimes. les services de sécurité et les ordinateurs. par terre).) risque de provoquer des interférences. D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de radio–navigation et de communication. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Ne pas obstruer les passages d’air du poste. panneaux. s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. les grouper. maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles. l’utilisation de câbles blindés. et les poser aussi bas que possible (ex. NON PAS les chariot. D Ne pas appuyer sur la gachette avant d’en avoir reçu l’instruction. D 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. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre l’appareil en service. le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. arrêter immédiatement l’appareil. D En utilisant des fourches de levage pour déplacer l’unité.1-3. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. DES ORGANES MOBILES peuvent provoquer des blessures. D D D D D L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. D Ne pas placer l’appareil sur. il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste. recouvrements et dispositifs de protection. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Réduire le courant ou le cycle opératoire avant de recommancer le soudage. de gougeage ou de soudage par points. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. D Maintenir fermés et fixement en place les portes. OM-353 Page 7 . D Ne pas diriger le pistolet vers soi. D Utiliser des pochettes et des boîtes antistatiques pour stocker. LE RAYONNEMENT HAUTE FRÉQUENCE (H. maintenir les câbles de soudage aussi courts que possible. restez à distance. au-dessus ou à proximité de surfaces infllammables.F. LA CHUTE DE L’APPAREIL peut blesser. D Ne pas s’approcher des organes mobiles. D Utiliser l’anneau de levage uniquement pour soulever l’appareil. Dangers supplémentaires en relation avec l’installation. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. D D D D D DES ORGANES MOBILES peuvent provoquer des blessures. D Utiliser un engin d’une capacité appropriée pour soulever l’appareil. respecter le cycle opératoire nominal. les bouteilles de gaz ou tout autre accessoire.

Lejeune Rd. OSHA 29 CFR 1910. 1-5. D. Quincy. de la National Fire Protection Association. il est alors recommandé de respecter les consignes ci–dessus. CGA Pamphlet P-1. suivant le jugement du comité. MA 02269. New York. n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. norme ANSI Z49. MA 02269. Cutting and Welding Processes. vente de normes.C. des champs magnétiques basse fréquence Le courant de soudage. 550 N. Quincy. Batterymarch Park. Suite 501. Arlington.1. Relier la pince de masse le plus près possible de la zone de soudure. norme AWS F4. 20402. Batterymarch Park. Miami FL 33126 Safety and Health Sandards. respecter les consignes suivantes : 1 2 3 4 5 Garder les câbles ensembles en les torsadant ou en les attachant avec du ruban adhésif. Principales normes de sécurité Safety in Welding and Cutting.1. un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves. Safe Practices For Occupation And Educational Eye And Face Protection.S. coupage et procédés connexes. Il y a eu et il y a encore un certain souci à propos de tels champs. 1235 Jefferson Davis Highway. du Superintendent of Documents. de l’American Welding Society.W. En attendant que les conclusions finales de la recherche soient établies. pour l’organisme. de l’American Welding Society. OM-353 Page 8 . Safe Handling of Compressed Gases in Cylinders. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. Toutefois. Rexdale (Ontario) Canada M9W 1R3. NY 10018. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets. Règles de sécurité en soudage. 550 N.2. Miami FL 33126 National Electrical Code. Government Printing Office. de l’Association canadienne de normalisation. de la Compressed Gas Association. il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. des études sont toujours en cours et les preuves continuent à être examinées.W. Cependant. norme NFPA 51B. pendant son passage dans les câbles de soudage. Washington. Garder le poste de soudage et les câbles le plus loin possible de vous. après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans. 1430 Broadway. Lejeune Rd. norme CSA W117. de l’American National Standards Institute.1-4. 178 Rexdale Boulevard. Mettre tous les câbles du côté opposé de l’opérateur. norme ANSI Z87. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances. NFPA Standard 70. de la National Fire Protection Association. VA 22202. Si vous êtes déclaré apte par votre docteur.1. Afin de réduire les champs électromagnétiques dans l’environnement de travail. U. causera des champs électromagnétiques.

1 2. Wear complete body protection. Do not weld on drums or any closed containers.3 4 4.SECTION 2 – DEFINITIONS 2-1.3 2 1 1. Keep your head out of the fumes. Have a fire extinguisher nearby and have a watch person ready to use it.1 4 4.3 2. Use forced ventilation or local exhaust to remove the fumes. Protect yourself from electric shock by insulating yourself from work and ground.1 3. Breathing welding fumes can be hazardous to your health. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Welding sparks can cause fires.2 2. Don’t weld near flammables. Use ventilating fan to remove fumes.2 3. Become trained and read the instructions before working on the machine or welding. Wear dry insulating gloves.3 3. Do not touch electrode with bare hand. 1 1. Arc rays can burn eyes and injure skin.2 1. Do not wear wet or damaged gloves. Use ear protection and button shirt collar.1 Electric shock from welding electrode or wiring can kill.2 1.1 1.1 3. 1. Do not remove or paint over (cover) the label.3 3.2 3 3.3 3 2 2. Welding sparks can cause explosion or fire.1 2. Disconnect input plug or power before working on machine.2 2. Wear hat and safety glasses.1 + 5 + + 6 5 6 + S-176 254-A OM-353 Page 9 . Use welding helmet with correct shade of filter. Keep flammables away from welding.

2V X U0 = 80V I2 U2 25% 310A/32.2V 1 U1 = 220 50 Hz U1 = 380 U1 = 415 IP 21S I1max = 117.8A I1Eff = 32A S-178 813-A OM-353 Page 10 .4V 18V 16.4V 60% 100% 310A 200A 155A 32. Rating Label For CE Products 1 1 ISO/IEC 974-1 7A/10.4V 60% 100% U0 = 80V I2 U2 310A 200A 155A 22.2-2.4V 28V 26.2A I1Eff = 59A I1max = 72.2A I1Eff = 36A I1max = 63.2V 5A/20.2V X 25% 310A/22.

Symbols And Definitions NOTE Some symbols are found only on CE products.2-3. A V Amperes Panel–Local Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding (SMAW) Volts Do Not Switch While Welding Arc Force (DIG) Spot Timer Output Circuit Breaker Remote Temperature Protective Earth (Ground) Alternating Current High Frequency Start Input Postflow Timer Preflow Timer High Frequency Continuous High Frequency Gas (Supply) Gas Input Gas Output Increase/Decrease Of Quantity On Off Percent Direct Current Balance Control Maximum Cleaning Maximum Penetration Electrode Positive Electrode Negative Crater Time Meter Single-Phase U0 I1 IP Rated No Load Voltage (Average) U1 I2 I1eff Primary Voltage U2 X I1max Conventional Load Voltage Line Connection Primary Current Rated Welding Current Duty Cycle 1 1 Single-Phase Combined AC/DC Power Source Degree Of Protection Maximum Effective Supply Current Rated Maximum Supply Current Hz Hertz Electrode Work Thickness Gauge Spark Gap S Seconds OM-353 Page 11 .

Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source.8*) 48 (49*) 575 V 30 (1.6*) 55 (57*) 220 V 77 (4. Single-Phase PFC** No PFC With PFC Rated Welding Output NEMA Class II (40) – 250 Amperes. 50/60 Hz. DC Mode B. 30 Volts AC.6*) 26 KVA 21 (0.5*) 48 (49*) 380 V 45 (2.6*) 80 V 21 S *While idling **Power Factor Correction 3-2.9*) 11 (11*) KW 8. Specifications Amperes Input at AC Balanced Rated Load Output. 60% Duty Cycle Amperes Input at AC Balanced Rated Load Output. 28 Volts AC.2 KW 11.SECTION 3 – INSTALLATION 3-1.3 (0. Single-Phase PFC ** No PFC With PFC 200 V 85 (4.2*) 34 (27*) 460 V 37 (2*) 24 (25*) 520 V 33 (1.7*) Amp Range Max OCV IP Rating 5–310 A 8.4 (0. 40% Duty Cycle 200 V 106 (4.89*) 15.6*) 19 (20*) KVA 17 (0.1 10/91 – SB-116 199 / SB-116 200 OM-353 Page 12 . A. Curves of other settings fall between the curves shown.6*) 76 230 V 92 (4*) 66 460 V 46 (2*) 33 575 V 37 (1.4 80 V 21 S *While idling **Power Factor Correction Rated Welding Output NEMA Class I (60) – 200 Amperes. AC Mode ssb1.4*) 37 (30*) 415 V 41 (2. 50/60 Hz.2*) 64 (51*) 230 V 74 (4*) 48 (49*) 260 V 65 (3.68*) Amp Range Max OCV IP Rating 5–310 A 11.3 (0.

Y Exceeding duty cycle can damage unit and void warranty. Reduce amperage or duty cycle before welding. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. thermostat opens. If unit overheats. Wait fifteen minutes for unit to cool.3-3. 40% Duty Cycle At 250 Amperes (60 Hz Models Only) 4 Minutes Welding 6 Minutes Resting 60% Duty Cycle At 200 Amperes 6 Minutes Welding 4 Minutes Resting Overheating 0 A 15 Minutes OR Reduce Duty Cycle duty1 4/95 / SB-116 198 OM-353 Page 13 . light goes on (CE models only). output stops. and cooling fan runs.

Dimensions And Weights Dimensions A B C D E Length A B F Front G E F G H H 6 Holes ST-154 792-B Height Width 30-3/4 in (781 mm) 19-3/4 in (502 mm) 27-1/2 in (698 mm) 27 in (686 mm) 26 in (661 mm) 25-1/4 in (642 mm) 1-1/2 in (38 mm) 1-1/8 (29 mm) 17-7/8 (454 mm) 19-1/4 (489 mm) 1/2 in (13 mm) Dia C D Weight 355 lbs (161 kg) OM-353 Page 14 .3-4. CE label located on rear panel. Selecting A Location 1 2 Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. 5 6 Plate Label (CE Models Only) Line Disconnect Device Location And Airflow 6 Locate unit near correct input power supply. extend forks beyond opposite side of unit. 18 in (460 mm) ST-800 402 / ST-117 264-F 3-5. 3 4 18 in (460 mm) 5 Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 3 4 OR 2 Rating Label (Non CE Models Only) Rating Label (CE Models Only. Movement 1 If using lifting forks. See Section 2-2) Use rating label to determine input power needs.

using shielded cables. and down low. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. If interference still occurs. or shielding the work area. Locate welding operation 100 meters from any sensitive electronic equipment. the user must take extra measures such as moving the welding machine.3-6. close together. such as on the floor. Be sure this welding machine is installed and grounded according to this manual. Tipping Y Be careful when placing or moving unit over uneven surfaces. S-0007-E OM-353 Page 15 . keep weld cables as short as possible. 3-7. Contact your distributor for the mm2 equivalent weld cable sizes. To reduce possible interference. Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 10 – 60% Duty Cycle 4 3 3 2 1 1/0 1/0 2/0 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Weld Output Terminals Welding Amperes 100 150 200 250 300 350 400 60 – 100% Duty Cycle 4 3 2 1 1/0 2/0 2/0 3/0 4 2 1 1/0 2/0 3/0 3/0 4/0 3 1 1/0 2/0 3/0 4/0 4/0 2-2/0 10 – 100% Duty Cycle 2 1/0 2/0 3/0 4/0 2-2/0 2-2/0 2-3/0 1 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 1/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 3-3/0 1/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 3-3/0 Work Electrode ST-154 795-C 500 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. using line filters.

0 to +10 volts dc output to remote control. Contact closure to A completes 24 volts ac contactor control circuit. 5 6 Regulator/Flow Gauge Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour) (9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections Y Turn Off power before connecting to receptacle. Remote 14 Receptacle Socket* Socket Information A B 24 volts ac. Chassis common. 4 2 3 Gas Valve In Fitting Gas Valve Out Fitting 6 Fittings have 5/8-18 right-hand threads 4 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. C A B K J I D Command reference. ST-154 795-C / Ref. 0 to +10 volts dc input command signal from remote control.3-8. ST-157 858 OM-353 Page 16 . Remote control circuit common. H C L N D M G E F ST-154 795-C A E K *The remaining sockets are not used. 3-9. Close valve.4 L/min) 7 1 7 High Frequency Control (see Section 4-1) 3 2 Ref. 1 5 115 V AC Receptacle Receptacle is protected from overload by circuit breaker CB1 (see Section 5-2).

3-10. Electrical Service Guide NOTE All values calculated at 60% duty cycle. 60 Hertz Models Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) 200 85 125 4 173 (53) 6 Without Power Factor Correction 230 74 110 6 158 (48) 6 460 37 60 10 291 (89) 10 575 30 45 10 455 (139) 10 With Power Factor Correction 200 55 80 8 86 (26) 8 230 48 70 8 114 (35) 8 460 24 35 12 186 (58) 12 575 19 30 14 189 (48) 14 S-0092-J 50 Hertz Models Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) Without Power Factor Correction 220 77 125 6 145 (44) 6 260 65 100 6 202 (62) 8 380 45 70 8 291 (89) 8 415 41 60 8 347 (106) 10 520 33 50 10 372 (113) 10 With Power Factor Correction 220 64 90 6 145 (44) 6 380 37 60 10 291 (89) 8 415 34 50 10 347 (106) 10 S-0092-J OM-353 Page 17 .

7/16 in ST-117 263-K OM-353 Page 18 . Reinstall side panel. Do not make connections for any other voltages. If jumper link label is missing from inside unit.3-11. 260 VOLTS L L 380 VOLTS L L 520 VOLTS L L S-047 672-A Connect GND/PE Conductor First GND/PE Earth Ground 4 L1 (U) L2 (V) 3 Connect GND/PE Conductor First Tools Needed: 3/8 in 3/8. 1/2. 3 220 VOLTS 380 VOLTS 415 VOLTS Input And Grounding Conductors L L L L L L S-083 566-C 2 230 VOLTS 460 VOLTS 575 VOLTS L L L L L L S-010 587-B 1 L L L L L L S-131 783-A Select size and length using Section 3-10. 4 Line Disconnect Device Select type and size of overcurrent protection using Section 3-10. Placing Jumper Links And Connecting Input Power Check input voltage available at site. 1 200 VOLTS 230 VOLTS 460 VOLTS Jumper Link Label Check label inside your unit– only one label is on unit. check rating label (see Section 3-4) for allowable input voltages. 2 Jumper Links Move jumper links to match input voltage. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. Y Only make connections for the voltages shown on the label inside your unit.

15 High Frequency Control See Section 4-11. See Section 4-5. See Section 4-4. 13 Power Switch And Pilot Light Use switch to turn unit and light On and Off. See Section 4-3. 7 8 See Section 4-6. 6 See Section 4-12. ST-154 795-C OM-353 Page 19 . 4 3 14 9 See Section 4-7. 10 Arc Force (Dig) Switch And Control See Section 4-9. 15 Ref. ST-117 264-F / Ref. 11 Postflow Time Control 2 1 See Section 4-10. Controls 1 7 8 9 2 3 6 10 11 12 5 13 4 5 Ammeter Voltmeter High Frequency Switch Output (Contactor) Switch Spot Time Switch And Control (Optional) Preflow Time Control (Optional) AC Balance Control Crater Time Control And Switch Amperage Adjustment Control And Switch See Section 4-3. 14 Output Selector Switch See Section 4-2. See Section 4-11.SECTION 4 – OPERATION 4-1. See Section 4-8. 12 High Temperature Shutdown Light (CE Models Only) Lights when unit overheats and shuts down (see Section 3-3).

Use switch to select (DCEN) Direct Current Electrode Negative.4-2. and then use a remote control. or if there is danger of falling. OM-353 Page 20 . but not necessarily the welding arc due to cable resistance. ST-181 675-A 4-3. Meters 1 1 2 Voltmeter Voltmeter displays voltage at the weld output terminals. 2 Ammeter Ammeter displays weld amperage output of unit. AC. Output Selector Switch 1 Output Selector Switch Y Do not use AC output in damp areas. 1 Ref. Y Do not change position of switch while welding or while under load. poor connections. or (DCEP) Direct Current Electrode Positive output without changing weld output cable connections. Use AC output ONLY if required for the welding process. etc. if movement is confined.

2 1 Spot Time Control Use control to set time (0–5. Spot time begins at arc initiation. and/or the operator wants to eliminate the crater at the end of the weld. Place switch in the OFF position to turn off spot weld circuitry. 1 4-5. 2 The (GTAW) TIG Spot process is generally used with a direct current electrode negative (DCEN) set-up. Crater Time Controls 1 Crater Time Control Use control to reduce current over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control. Put switch in the OFF position while doing Shielded Metal Arc Welding (SMAW). OFF – provides no crater time. with the fusion method.7 seconds) for Gas Tungsten Arc (GTAW) spot welds. Postflow starts when the remote contactor is opened.4-4. OM-353 Page 21 . the timer stops but does not reset. Place switch in the OFF position for Shielded Metal Arc Welding (SMAW). Application: 2 Crater Time should be used while GTAW welding materials that are crack sensitive. When the spot time has ended. Application: TIG spot welding is used for joining thinner materials that are in close contact. Spot Time Controls 1 Spot Time Switch Place switch in the ON position to turn on spot weld circuitry. If the arc is broken during the spot time cycle. 2 Crater Time Switch ON – provides crater time. weld output stops. The spot timer resets after the contactor opens. Note: This applies if the operator is using an on/off only type control to start and stop the welding process. A good example would be joining coil ends.

approximately a 0. To produce a good weld. process variables.10 in (2.4-6. may help to restabilize the arc. Set control to 7 and adjust as necessary. S-0795-A OM-353 Page 22 . 1 Setting Balanced 3 Output Waveforms 50% Electrode Positive 50% Electrode Negative Arc More Penetration 32% Electrode Positive 68% Electrode Negative 55% Electrode Positive 45% Electrode Negative 10 More Cleaning 0 Ref. Rotating the control towards 0 provides more cleaning action of the workpiece. Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. the wave shape provides equal penetration and cleaning action. Joint configuration. and oxide thickness may affect setting. increasing the Balance control towards maximum penetration. excess cleaning is not necessary. When the control is in the Balanced position. Application: When welding on oxide forming materials such as aluminum or magnesium. Rotating the control towards 10 provides deeper penetration. AC Balance Control 1 AC Balance Control Balance Control (AC GTAW): Control changes the AC output square wave. If this condition occurs. only a minimal amount. set-up.5mm) of etched zone along the weld toes is required.

2 For remote control. For remote control. and preset amperage on ammeter (see Section 4-3). and connect remote control device (see Section 3-8). For remote amperage control. place switch in REMOTE 14 position. 2 Amperage Control Switch Use switch to select way of controlling amperage adjustment. When On is selected. HF and gas control are disabled. OM-353 Page 23 . For front panel control.4-7. Output (Contactor) Control Switch Y Weld output terminals are energized when Output (Contactor) switch is On and Power is On. Amperage Adjustment Controls 1 1 Amperage Adjustment Control Use control to adjust amperage. and connect remote control device (see Section 3-8). For front panel control. place switch in REMOTE 14 position. the range of the remote amperage control is 5 to 200 A. For example: If front panel control is set to 200 A. For spot welding. This control may be adjusted while welding. 4-8. front panel control setting is the maximum amperage available. place switch in the PANEL position. use Amperage Adjust control to select from 5–310 amps of peak amperage (see Section 4-5). place switch in ON position. 1 1 Output/Contactor Switch Use switch to select way of controlling unit output.

4-9. and to prevent contamination of tungsten and weld. When switch is in the OFF position. 1 OM-353 Page 24 . shortcircuit amperage at low arc voltage increases. Set at 0 for GTAW welding. Postflow Time Control 1 Postflow Time Control Use control to set length of time (0–70 seconds) gas flows after welding stops. 1 2 4-10. Place switch in the OFF position while performing Gas Tungsten Arc Welding (GTAW). It is important to set enough time to allow gas to flow until after the tungsten and weld puddle has cooled down. short-circuit amperage at low arc voltage is the same as normal welding amperage. Application: Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage. When setting is increased. no additional amperage is available at low arc voltages. Application: Postflow is required to cool tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance. Arc Controls 1 Arc Control (Dig) For AC And DC SMAW Welding When set at 0. and reduces electrode sticking while welding. 2 Arc Control Switch Place switch in the ON position to turn on arc control circuitry.

and turns on whenever arc is broken to help restart arc. Application: HF Continuous is used when the AC GTAW process is required. Preflow also aids in consistent arc starting. 4-12. 2 High Frequency Intensity Control 2 Use control to change amount of HF energy used to start and maintain the arc. Application: Preflow is used to purge the immediate weld area of atmosphere. High Frequency Controls 1 Y Place High Frequency switch in Off position before using the shielded metal arc welding (SMAW) process. CONTINUOUS – (Down position) provides HF continuously throughout the weld. High frequency turns on to help start arc when output is enabled. Preflow Time Control (Optional) 1 Preflow Time Control Use control to set the length of time (0–15 seconds) that gas flows before an arc is started. Use OFF for SMAW (stick electrode) welding.4-11. OFF – provides no HF. High frequency turns off when arc is started. Set as low as practical to prevent interfering with electronic equipment. 1 OM-353 Page 25 . 1 High Frequency Switch START – (Up position) provides HF for arc starting only. Application: HF Start is used when the DCEN GTAW process is required.

and gas flow stop. Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens.SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. 3 Months Replace Unreadable Labels Repair Or Replace Cracked Weld Cables Clean And Tighten Weld Terminals Adjust Spark Gaps 14-Pin Cord Gas Hose Torch Cable Replace Cracked Parts 6 Months Blow Out Or Vacuum Inside. output to the 115 volts ac duplex receptacle. Routine Maintenance Y Disconnect power before maintaining. Press button to reset breaker. ST-154 795-C OM-353 Page 26 . During Heavy Service. Clean Monthly OR 5-2. high frequency. 1 CB1 Ref.

Place gauge of proper thickness in spark gap. unit on. proceed as follows: 3 Adjustment Screws Loosen screws. Tools Needed: Ref. if necessary (see Section 3-11). unit completely inoperative. If adjustment is needed. If remote is not being used. OM-353 Page 27 . place Output switch in Remote 14 position. No weld output. or replace remote control. Adjust other gap. Troubleshooting Trouble No weld output. Allow unit to cool with fan On (see Section 3-3). Check and replace line fuse(s). do not clean or dress tungsten. ST-154 795-C 5-4. Open access door. Check for proper jumper link position (see Section 3-11).5-3.203 mm). and make sure remote control is connected to Remote 14 receptacle. Check for proper input power connections (see Section 3-11). place Output (Contactor) switch in On position. Have Factory Authorized Service Agent check control board PC1. Unit overheated. If using remote control. 2 3 3 2 1 Spark Gap Normal spark gap is 0. Close access door. repair. Check.008 in (0. Remedy Place line disconnect switch in On position (see Section 3-11). 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap. Adjusting Spark Gaps Y Turn Off power before adjusting spark gaps. 1 4 4 Tungsten End Of Point Replace point if tungsten end disappears. Tighten screws to 12 in/lbs torque (overtightening will deform plastic base).

and make sure remote control is connected to Remote 14 receptacle. Reduce gas flow rate. Check High Frequency control setting (see Figure 4-1). difficulty in starting GTAW arc. If remote is not being used. Erratic or improper weld output. Have Factory Authorized Service Agent check control board PC1 and hall device HD1. no gas flow. See torch Owner’s Manual. Lack of high frequency. Check for water in torch. and repair torch if necessary. Select proper size tungsten. Wandering arc – poor control of direction of arc. Have Factory Authorized Service Agent check Amp Adjust control and control board PC1. Have Factory Authorized Service Agent check control board PC1. No AC Balance control. Properly prepare tungsten. Weld output always above or always below set value. place Output switch in Remote 14 position. Have Factory Authorized Service Agent check fan motor. Have Factory Authorized Service Agent check control board PC1 and hall device HD1. Check cables and torch for cracked insulation or bad connections. place Output switch in On position. NOTE: fan only runs when cooling is necessary. No high frequency. OM-353 Page 28 .Trouble Fan not operating. Properly prepare tungsten. Check position of Output Selector switch (see Section Figure 4-1). Check spark gaps (see Section 5-3). Unit provides only maximum or minimum weld output. Be sure electrode holder cable is not close to any grounded metal. Remedy Check and remove anything blocking fan movement. Select proper size tungsten. If using remote control. Use proper size and type of weld cable (see Section 3-7). No control of weld output. Shield weld zone from drafts. Repair or replace. and no 115 volts ac output from duplex receptacle. Increase postflow time. Clean and tighten all weld connections. Tungsten electrode oxidizing and not remaining bright after conclusion of weld. Reset circuit breaker CB1 (see Section 5-2). Have Factory Authorized Service Agent check AC Balance control and control board PC1. Check and tighten all gas fittings.

5-5. Circuit Diagram SC-188 161-A OM-353 Page 29 .

Welding Processes Using HF 1 HF Voltage GTAW – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Sources Of HF Radiation From Incorrect Installation Weld Zone 11.SECTION 6 – HIGH FREQUENCY (HF) 6-1. 2 Flux 6-2. 12 50 ft (15 m) 10 9 8 7 3 13 2 14 1 4 5 6 S-0694 Sources Of Direct HF Radiation 1 2 3 4 HF source (welding power source with built-in HF or separate HF unit) Weld Cables Torch Work Clamp 5 6 7 8 9 Workpiece Work Table Input Power Cable Line Disconnect Device Input Supply Wiring Sources Of Reradiation Of HF 10 11 12 13 14 Ungrounded Metal Objects Lighting Wiring Water Pipes And Fixtures External Phone And Power Lines Sources Of Conduction Of HF OM-353 Page 30 . 2 1 Work Gas Tungsten Arc Welding (GTAW) Work Submerged Arc Welding (SAW) high_freq1 7/95 – S-0693 1 SAW – helps arc reach workpiece through flux granules.

S-0695 1 HF Source (Welder With Built-In HF Or Separate HF Unit) Ground metal machine case. and worktable. OM-353 Page 31 . line disconnect device. 3 4 Weld Output Cables Conduit Joint Bonding And Grounding Keep cables short and close together. 5 Water Pipes And Fixtures 8 Metal Building Panel Bonding Methods Bolt or weld building panels together. 10 Overhead Door Track Ground the track. Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6. 2 Welding Zone And Centerpoint A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions.6-3. 7 Grounding Rod Consult the National Electrical Code for specifications. install copper straps or braided wire across seams. S-0695 / Ref. input supply. Ground conduit every 50 ft (15 m). Correct Installation Weld Zone 50 ft (15 m) 6 50 ft (15 m) 4 5 1 2 7 3 7 Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Wire Nonmetal Building Ground Workpiece If Required By Codes 8 7 7 10 Metal Building 9 Ref. 9 Windows And Doorways Ground water pipes every 50 ft (15 m).4 mm) mesh. work output terminal. 6 External Power Or Telephone Lines Locate HF source at least 50 ft (15 m) away from power and phone lines. and ground frame. Electrically join (bond) all conduit sections using copper straps or braided wire.

7–2 22 . Hardware is common and OM-353 Page 32 1 ST-120 135-R not available unless listed.SECTION 7 – PARTS LIST 17–Fig.7–3 27 26 8 23 28 .7–4 18 19 20 13 30 31 14 16 12 11 15 21 10 24 9 25 7–Fig. Main Assembly 29–Fig. Figure 7-1.7–5 4 3 6 5 2–Fig.

. . 6-32 x . . . warning electric shock can kill etc . . . . . . . . . current 300A . . . . . . . . . 157 196 . . C11. . . . . . . . . . . . . . . Part No. . . . . . . . . . . . . . . . . . . . . . si diode (Fig 7-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . 7 . . . . . PLG51 . . . . . . . . . . . . . . . . 180 674 . . . . . . . . . . . . . . . . . PANEL. . . . . . . . . . . . . . . . . . . . 156 313 . . . . . . . . . F1. . . . . . . . . .500 OD x 17ga x 1 . . . . . . . . . . . . . . PLG11 . . 010 150 . . . . . . 26 . . . . . . . . . . . . . . . . . . .437 lg . . . . . . . . . . . 191 887 . . . . . . . . . . . . . . . . . . . . . PLG54 . . . BUSHING. . . . . . . . . . . . . . . . . . . . TRANSFORMER. . OM-353 Page 33 . . . . . . . 21 . . . . . . . . . . . . . . . . . mintr gl slo-blo 10A . . . . .2 . . . . . . . . . . . . . . . . . . . . . . . . . PLG10 . 23 . . . . . . . . . . . . . . BUSHING. . . . TRANSFORMER. side . . . . 21 . . . . . . . . 30 . . . . . . . . . . . . . . . . TRANSFORMER. . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 2 3 1 4 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 2 1 1 1 2 1 1 2 +When ordering a component originally displaying a precautionary label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . PANEL. . . 117 803 . . . . PC1 . . . upright . . . . . . 24 . . . . . . 098 376 . . . . . . . . . . . . . 8 . . . . . . . FL1 . . . . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . pwr main 260/380/520 (consisting of) . stl . . . . . . . . . . . . . . . . . CONNECTOR PLUG & SOCKETS . 11 . . . . . . . 4 . . . . . . . . . . . . . . 6 screw . . . . . . . . . . . . . . . . . . . . SWITCH. . . . mtg components . . . . . . . . . . . . . . . . 133 061 . . . . . . . . . . . 182 605 . . . . . PLG55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . THERMOSTAT. . . . . . . . . . . . . . . . . 25 . . . . . . . . . 16 . . . . . . . 057 357 . . . . . . . . INSULATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR. . . . . . NC open 135C w/insulator . . . . . . . . . . . . . . . . . . . . . 168 891 . . . . . . . . . . . . . . . . . TP2 . . . . . . . . . . . T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 034 587 . . . . . . . . . . . . . . . . . . . . the label should also be ordered. . . . . . . FRAME. . . . . . . . . . TRANSDUCER.937 ID x 1. . . . . . . . 130 203 . . . . . . . . . . . . . use only Manufacturer’s Suggested Replacement Parts. . . . . . TRANSFORMER. . . . . . . . pwr main 230/460/575 (consisting of) . . 130 204 . . . . 026 627 . . . . 9 . . . . . . . . . . . . . . . . . . 180 672 . . . . . 28 . . . . . . . . . . . . . . . . . . . . lift eye . . . . . 10 . . . . 073 756 . . . 18 . . . . . . . . . . . . . . . LABEL. . . . . . . . . . PC card No. . . . . . . . . . . . . . . . . pwr main 220/380/415 (consisting of) . +182 606 . . . . . . . . . . . . . . . . . pri . . . . . . . . . . FILTER. GROMMET. . . . . . . TERMINAL ASSEMBLY. . . . Fig 7-5 . . . . . 115 093 . . . . . . . . . . . . . . . . . . . . . . pwr main 200/230/460 (consisting of) . . . . . Description Figure 7-1. 171 677 . . . . . . . PLG3 . . . . . . . . . . . . . . .312sq . . . . . . . . . . . . . . . COVER. . . . . . . . . . . . . . . . . . . . Model and serial number required when ordering parts from your local distributor. . . . . . . . 109 035 . . . STAND-OFF. . . . . . . . . . . 085 874 . . . . . . . . 168 071 . . . CONNECTOR PLUG & SOCKETS . . . . . elctlt 4000uf 100VDC . . . . . . . . . . . . RECTIFIER. . . . . . screw No. . . . . . . . . 134 201 . . . . . . . . . . . . . . . . . . . . R5 . . 010 494 . . 187 642 . . . . . 27 . . . . . . . . . . . TP1 . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . HOLDER. . . . . . . . . . . lifting . . PANEL. CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . Fig 7-2 . . . . . . . plrty/changeover . . . . . . . . . . . 12 . . . . . . . CIRCUIT CARD. . . . . . . .2 . . . . . . . . . . . . . . . . . . . . . . . . . . S4 . . . . CONNECTOR PLUG & SOCKETS . . 070 026 . . 3 . . . . HD1 . . . . T1 . . . . . . . . . . . . . . . . . . . . 031 668 . . . . . . . . . . . CAPACITOR. . WW fxd 10W 1K ohm . . . . . . . . . . . TE1 . . . . . . . . . . . . . 108 105 . . . . . . . . . . . . . NC open 80C close 50C . . . 020 520 . . . . . . . . . . . . . . . . . snap-in nyl . . . . 115 091 . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . .375 ID x1. . . . 168 809 . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . . . . . . . . . . 181 106 . . . . . . . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . mtg rectifier . . . . . . . CLAMP. . . . . . . . . 180 673 . . . . . . . . . . . .750mtg hole . Dia. 111 634 . . . . . SR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 826 . . . . . . . . . . . . . . . . . . . . 084 171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Assembly Quantity . . . STAND-OFF. . . . . . . . . . . . . front w/components . . . . . . . To maintain the factory original performance of your equipment. . . . . . . . . . . . . . . C13 . PLG1. . . . . . . . BRACKET. . . . . . 31 . . control . . . . . . . top . . T1 . . . . fuse mintr . . . . 083 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF SUPPORT. . . .05uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . capacitor 2. . . . . Z1 . . . . . . 5 . . . . . . . . 2 . . . . . . . No. . . 22 .500 high . . . . . . . . . .125mtg hole . . . . . . . . . . T1 . snap-in nyl 1. . . . . . CAPACITOR. . . . PANEL. 181 101 . . . . 21 . . . . . line power 115/250V . . . C2 . . . THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625 lg . 21 . . . . . . .Replace Coils at Factory or Authorized Factory Service Station Item No. . . . . FUSE. . 114 722 . . . . . . . . . . . . . TUBING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR . . . . . . . . . . . . . 1 . . . . . . Mkgs. . . . . . . . . . 097 750 . . . . . . . . . . . . .500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig 7-4 . . . . . . . . . . . . . . . . . . . . . 6-32 x . . . . . . . . . 17 . . . . . . . rear w/components . . . . . . . . . . . . cer disc . . . . . . . . . . . . . . . . . . . . . . . . . 164 899 . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/10 panel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET. . . . . . . . .

. Front w/Components OM-353 Page 34 . Hardware is common and 8 9 10 not available unless listed. 2 4 1 3 5 6 7 4 12 11 13 Includes Item 26 29 28 14 27 1 26 16 15 25 24 23 22 17 18 Fig 7-6 19 21 20 ST-120 088-G Figure 7-2. Panel.

. . . . . . . . . . . . . . . . . . . . . . . . . . 2 . handle switch . . . . . . . DOOR. . . . . . CONNECTOR & SOCKETS . . . . . . . . . S5 . . . . . . .562mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 052 192 . . . . . . . . . . . . . . . . . . . . . . . . S1 . . . . . . . . volt AC/DC 0-100 scale . . . . . . . . . . R1. . . . . . . . . . . . . . . . . . . . . . . . . . Description Figure 7-2. . . . . . . . . . . . . . . . . . . . 18 . . . PIN. . 9 . . . . . . NAMEPLATE. . . 8 . . . . . . . warning electric shock etc . tgl SPDT 15A 125VAC . . . . 20 . . . . PIN. . . . . . . . . . SWITCH. . . . . CONTROL PANEL. . . . . . . . . . . . . . 169 136 . . . . . . . . . . . . . . . . . . . . . . . . indicator . . . . . TIMER. . . . . 181 096 . . . . . . BRACKET. . . . . . spring CS . . . . . . . . . . . . . . . 12 . . . S2 . . . . . . . . . . . . 004 189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . PL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ind wht lens 28V (power indicator) . tgl 4PDT 15A 125VAC . . . . . . . . . . . delay on make – postflow (consisting of) . . . . . . . PLG6 . . LABEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB. . . . . . . . . . . . . KNOB. . . . . . . . . . . . .7 . . . . . . . +181 589 . R11 . . . 128 230 . . . snap-in nyl . . . . . . . . . . . 157 958 . . . . . R3 . . . . . . Dia. . 134 327 . . plrty/changeover switch . . . . . . . . . . . . . . . . POTENTIOMETER. . Fig 7-6 . (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model and serial number required when ordering parts from your local distributor. . . . . . . . . . . . . . . . . . . . . . . . Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . POTENTIOMETER. . . . . 131 054 . . . . . LABEL. . . . pointer . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . 115 920 . . . . . . . . . . . . . . 088 409 . . . . . . . . . . . . . . 10 . . . . . . . 155 500 . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . 052 769 . . . . . . POTENTIOMETER. . . . . . . . . . . . 13 . . . BUSHING. . . . . . . . 16 . . . . . . . . . . C sltd sft 1/T 2W 1K ohm . . . . . postflow . . . .375 ID x . . . . . . . . . . . . . . . . . warning general precautionary . . . . . . . . . . . . . LIGHT. . . . use only Manufacturer’s Suggested Replacement Parts. . . . . . . . . . . . . . . . . . . Front w/Components (Fig 7-1 Item 29) Quantity . . . . . . . . . 052 370 . . . . . . . . . . the label should also be ordered. PL2 . . . . . .Item No. LED. . . . . . . . . . . . . . . . . V1 . . . . SWITCH. . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S3 . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 097 922 . 6 . . PLG5 . . C sltd sft 1/T 2W 5 meg ohm . . . . . . 171 420 . . . . . . . . SWITCH. . . . . . . . mtg circuit card . . pointer . . . . . . METER. . . . . 4 . . . . . . . . 175 952 . . . . . . . . . . . . . . . . . . TD1 . 030 109 . . . . . . . . . . . . . 5 . . . . . . . . . . . .156 x . . . . . . . . amp AC/DC 100MV D-300 scale . . . . . . 25 . . . . . . Mkgs. . . . . . 109 013 . . . . . . C sltd sft 1/T 2W 5K ohm . . . . . . . . . . . . . . . . . . . . 176 882 . . . . . . . . lower . . . . . front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB. . . . . . . . . . . . . . . . . . . METER. . . 035 897 . . 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . access front . . . 097 924 . . . . . . . . . 11 . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . EXTENSION. . 14 . . . . 24 . . . . . . . . . . S6. . . . 15 . . . . . . . . . . . . SWITCH. . . yellow (50Hz model) . . . . PANEL. . A1 . tgl SPST 15A 125VAC . 128 757 . . . . . . CIRCUIT CARD. . . . . . . . . . . . . . . . . . . 106 398 . . . . . . . . . . . . . . . 039 449 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 011 609 . . . . . HANDLE. 28 . . . . . 1 . . . . . . . .625 . . . tgl DPST 60A 600VAC . . . . . . . . . . . . . . . . Part No. . . . . . . . . . . . . . . . .250 . . . . . . . . . 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH. . . . . . . . . . . 21 . . . . . . . . . . . 044 723 . . . . . . . . . . . . . .2 . .156 x 1. To maintain the factory original performance of your equipment. . . . . spring CS . . . . . . 135 635 . . . . . OM-353 Page 35 . . . . . . 22 . . 27 . . . . . . . . . . . . . . . 030 684 . tgl 2PDT 15A 125VAC . . . . . . . . 3 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 +When ordering a component originally displaying a precautionary label. . . . . . . . . . .

. NC. . . 173 283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 x . . . 1 . . . 5 . . . . . . . . . 037 956 . . . . . . . . . . . . plenum 14 in (50Hz only) . . Hardware is common and not available unless listed. . . . . . . . . . . . . . . . . . . . . THERMOSTAT. . . . . . . . use only Manufacturer’s Suggested Replacement Parts. . 2 1 3 1 1 1 1 1 1 1 . . . 1/12 hp 230V 1550 RPM 50/60Hz 1. . . . . R4 . SCR 300A 300V . . . . . . . . . . . . Rectifier. . . . Si Diode Item No. . BLADE. . FM . . . . . . Panel. . . .. .. . . . . .375 bore . . . .Item No. . . . . . . . . RESISTOR. . . . . . . . . . . . . .. . . . . . . . . . . . Rear w/Components To maintain the factory original performance of your equipment. . . . . 4 . . . 124 274 . . . . . .. . . . . . . . . . . . OM-353 Page 36 . . . . . . . . . . . . . . . . . . . . . . . . PIN. . Dia. . . THYRISTOR. . . . . . . . . SCR1-4 .. . . . 4 . spring rectifier . . . . . . . .. . . . . . . . . . . CHAMBER. . . . . . . . . . . . . . . . . . . . . . . .250 . . . . . . . . . . 4 5 6 ST-120 089-F Figure 7-4. . . . . . . . . . . . . . . . . . PLG53 . . Dia. . . . . . . . . . . . . WW fxd 175W 20 ohm . .. . . . PANEL. . . 2 . . . . . . . MOTOR. . . . . . . . . . . . . . . . . 028 516 . . . . . . . . . . . . . . . . . . 116 190 . . . . . .. . . . rear . . . cable clamp (50Hz model) . . C7-10 . . . 6 . . . . . .. . . . . . . . . . . . . .5A . . 2 . . . . . . . .. . . . . . . Part No. . . . . . . . . . . . . . . . . . . . . spring CS . . . . . . 173 714 . .. . . . . . 5 . . . . . . . . . . . open 125°C . . . . . . . 115 092 CAPACITOR. . . . . . . . . . . thyristor . . . . . . . . . . . 180 165 . . . 5 6 ST-120 205-A Figure 7-3. . . . . . . . . Rear w/Components (Fig 7-1 Item 17) Quantity . . . . . TP3 . . rect 275A 300V SP . . 168 898 . . . . . . Part No. . . . . . . . . . . . . . . . . . . . . . . . Rectifier. . . . . . . . . . . . . . . 115 114 . . . . . . . . . Hardware is common and 1 not available unless listed. . . . . . . . . . . . . . . . . . . . Model and serial number required when ordering parts from your local distributor. . . . . . . . . . . DIODE. . . . mtg fan motor . . . . . . . . . . . . . Panel. . . . . . . . .. Si Diode (Fig 7-1 Item 2) . . . . fan 14 in 3wg 28deg . . . . . . . . . . CLAMP. 6 . . . . . . . BRACKET. . . CLAMP. . . . . . . . . . 186 949 . 3 2 4 2 5 4 2 1 1 4 2 2 1 . . . . . . 181 099 . . . rectifier . . . 181 106 Description Figure 7-3. . . . . . . . 3 . . . . . . . . . . . . . CONNECTOR PLUG & SOCKETS . . . . Quantity . . . . . . . . . . . . . D1 . . . . 176 272 . . . . . . . . . . Mkgs. . . . . . . . 1 . . . . . . 031 689 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description Figure 7-4. . . .. . CONNECTOR. . . . . . .. Mkgs.. . 166 667 . . 3 . . . . .

. . . 108 023 . . 7 . . mtg relay . . . . . . . . . . . . 072 253 . . 1T . 5 . . . . Hardware is common and not available unless listed. . encl 24VAC DPDT . . . . 035 704 . . 3 .Item No. . . . . . . . CR1 . . . . . . . . . . WW fxd 10W 1K ohm . . . . . . . . . LINK. . . . . . . . . . . .. . . . . . . . . . Mtg Components To maintain the factory original performance of your equipment. . . . . .. . . . . . Mkgs. . .05uf 500V . C20 . . . . integ 40A 800V . . . . . . . . . . . . 000 770 . . . . Description Figure 7-5. . . . . encl 24VDC 3PDT . cer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR. . . . . . . WW fxd 100W50 ohm . 117 372 . . . . OM-353 Page 37 . . . . . . . . . . . . . . 119 834 . . .. 118 625 . . . . . SR2. single connection 10-32 . . . . . . . . . . . . . . . . . . CAPACITOR. 110 386 . . . CR2. . . . . . . . .5uf 200VDC 100 ohm . . . . . R7 . . . . . . . . . . . . . . . . . . . . . . RECTIFIER. . . . 1 . 11 . . . 2 . . . . .6 . . poly metal film . . . . encl 24VDC DPDT . . . . 6 . . . . . . . . . Part No. . . .. . . . . . . . . . . . .. . RELAY. . . . . . . . . . . . . . jumper term blk 10A . . . . . . . . . use only Manufacturer’s Suggested Replacement Parts. . . . . 117 721 . . . . . . . . . . .. . . . Model and serial number required when ordering parts from your local distributor. . . . . Dia. . . . . SN1. . . . . . . 186 468 . . PANEL. . . . SNUBBER. . STUD. . . . . . . . Panel. . . 4 . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 1 2 2 1 1 1 3 1 1 . .. . . . . . . . Panel. . . . . . . Mtg Components (Fig 7-1 Item 7) Quantity . . . . . . . . . . . .3 . . . . . . . . . . . .. . . . . . . . . . . 10 . . . . . . . .. . . . . . 1 2 11 3 6 10 3 4 5 6 9 8 7 ST-120 090-F Figure 7-5. . . 8 . . term 10A 15P . . . .. . . . . . . . BLOCK. . . . . . . . . RELAY. . . . . . . . . . . R6 . . . . . . . . . . . . RESISTOR. . . . . . 117 803 . . . . . . . . . . CR5 . . . . . . . . . . . .2 . . . 9 . . . . . . . . . . . . . . . . 2T . . . . . 052 964 .. . . . . RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

14 5 15 17 16 13 3 2 4 7 1 8 9 10 6 11 18 23 22 19 21 20 ST-120 003-Q Figure 7-6. Lower Front OM-353 Page 38 .. Hardware is common and not available unless listed. Control Panel.

. . . .. . . . . . . . .002uf 10. . .. . . . . . . . 4 . . R13 . . . .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . 6 .. . . . . . . . . . . . PANEL. . . . . . . . . . .. mounting components .. . . . . . . . . . . .. . . . . 19 . . .Item No. . . . . . . . . . . . . . . . . . . . . . KNOB. . C4 . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . ..05uf 500 VDC . . . . . . . . . 15 . . 18 . . . . . . . . . . . speed 1. . . . . . . 23 . .. w/leads . . . . . . . . . . . . . . . .. . . . . .. . . . . . OM-353 Page 39 . . . . . . . . .. . . . . . . . . . . . . . . . . T3 . . . . points . . . . .. . . . . . . . . . man reset 1P 15A 250VDC . . . . . . Mkgs. . . . . . . . . . . . . . . . . .002uf 4400VAC panel mtg . . . . . . . . . . . .. . . door access HF . . . . . . . . .. . . . . . . . high voltage 115V . . . . . .. . . . . . . . . . Lower Front (Fig 7-2 Item 18) Quantity . . . . . . . . . . . . . . . . .. Part No.01uf 500VDC .. . . . . .. . . . CAPACITOR. . . . . . . . . . . .. . . . . . . ... . . . . . GS1 . . . C6 . . . . . . . . . . . . . . . . . . VALVE. . . . . . 8 . . . . . SPARK GAP ASSEMBLY (consisting of) . . . . . . . . 7 . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . BASE. . . . . . . Model and serial number required when ordering parts from your local distributor. . . . Control Panel... . . . . . . . . . .. . . . . . . . . . . . . . . . 22 . . . . . . . . . . .. . . . . . . . use only Manufacturer’s Suggested Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . polyp met film .. . . . .. . . cer disc .625-18R . . . . . . . . . . . . . .. . . . . . . . . . . . . . str dx grd 15A 125V . Description Figure 7-6. . . . . . . . . CAPACITOR. . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . C15 . . . . . .. . . . . .. 16 . . . .. . . . . . . . . . mica . .. . . . . . . . . . . w/fitting and leads (consisting of) . CAPACITOR. . . . . . . . . . . . . . . . . . . .. . . . . . . . RC2 . . . .. . . . . . . . . NUT. . . . . . . . . . . . . . . . spark gap . . . . .. . . . . . 1 1 3 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 *Recommended Spare Parts To maintain the factory original performance of your equipment. . . . .. . . . . RC1 . . . . . T2 . . . . . . . . . . . . . .. . . RESISTOR. . . . . . . .000V panel mtg (CE Models Only) . . . . . . . . . . . . . . . . . . . .. . . . . . . CIRCUIT CARD ASSEMBLY . . . . . . pipe brs elbow 1/4NPT x . . . .. . . . 171 652 137 429 132 433 157 959 153 501 164 290 131 204 604 176 170 920 093 995 198 547 199 854 199 855 199 856 *196 455 174 070 191 944 181 107 201 197 096 761 074 398 174 692 039 047 174 036 035 601 010 296 131 203 174 038 097 922 010 357 . . PANEL. . . . . . CAPACITOR. . . . . . . . . . . . . . . . . . . TRANSFORMER. .. . . . . . pointer .. . . .. . BRACKET. . .. . . .. . . . . . . PC2. . . C3 . . . . . . . . . . . . . . 21 . . . CAPACITOR. . . .. . . . . . . . . . . . . . . . . . .. 3 . . . . . . VALVE. .. . . 11 . . . COIL. FITTING. . R25 . . TERMINAL.. . . . . front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . ... .. pwr output . . CIRCUIT BREAKER. . . . . . . . . . . . . . 5 . . . . . . . .. . . CONNECTOR & SOCKETS . .. . . . . . . . . . . . . . ... . . . . . . . .. 2 . . . . . . . . . . . .. . .. . . . . . 17 . . . . polyp met film . . . . . . . . . .. . . WW 25W 1. . . .. . . . . . . .. . . . . . . . . . .. . . . .3K . . . . . . HF coupling . . . . . . . . .. 9 . . . . 16 . . . .. . . . . . . . . . . . . . . . . . . . . . POINT. . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . .. . . HOLDER. . . . . RESISTOR ASSEMBLY. . . . . . . . ... RECEPTACLE.. . . PLG21 . . . . .. . . . . . .00L . . .. . . . . . . . . C2 W 3. . . . . 20 . . polyp film . . . . . . . . . . . . RHEOSTAT.. . . . .. . . . 13 . . . R8 . . . . . . . . . . PLG3 .. . . .. . . . .. C4 . 10 . CAPACITOR . . . .. . Dia. . . . .. . . . . .. . .. . . . . . . . . 115VAC 2 way . . . . . . CB1 . . . . . . .250 ID w/set screw . . . . . . .. . . . .. . .. . . . . . . . . . C14 . . . .5 ohm . . . . . . . . . . G . . . . . . . . . . . spark gap . . . . . . . . . .. . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . .. CONNECTOR & SOCKETS .875dia x . . .. . . . .. . . . . . . . . . . .. . . . PLG4 .. . .

Notes OM-353 Page 40 .

.

.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. reliable response you need. OPERATION OF LAW. or equipment which has been used for operation outside of the specifications for the equipment. miller_warr 7/00 3. WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. CUSTOM OF TRADE OR COURSE OF DEALING. * * * * * * APT. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. slip rings. such as engines or trade accessories. Factory at Appleton.. or equipment which has not had reasonable and necessary maintenance. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer. 5 Years Parts – 3 Years Labor Call 1-800-4-A-MILLER for your local Miller distributor.Effective January 1. AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH. 2000 (Equipment with a serial number preface of “LA” or newer) Warranty Questions? This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. special or consequential damages. 3. * * 2. 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.O. 1. or F. but may vary from state to state.B. or the exclusion of incidental. Wisconsin. This warranty provides specific legal rights. In Canada. if any. at which time Miller will provide instructions on the warranty claim procedures to be followed. such as contact tips.O. TO THE EXTENT PERMITTED BY LAW. 6 Months — Batteries 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets . Most replacement parts can be in your hands in 24 hours. LIMITED WARRANTY – Subject to the terms and conditions below.B. and other rights may be available. or equipment that has been improperly installed. where authorized in writing by Miller in appropriate cases. 2. at a Miller authorized service facility as determined by Miller. Support Need fast answers to the tough welding questions? Contact your distributor. brushes. INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE. Miller Electric Mfg. but manufactured by others. relays or parts that fail due to normal wear. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. Some states in the U. TORT OR ANY OTHER LEGAL THEORY. Service You always get the fast. Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. or (2) replacement. GUARANTY OR REPRESENTATION AS TO PERFORMANCE. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. In the event of a warranty claim covered by this warranty. ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. so the above limitation or exclusion may not apply to you. 5. or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.. legislation in some provinces provides for certain additional warranties or remedies other than as stated herein. Consumable components. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser. cutting nozzles. Appleton. (3) the reasonable cost of repair or replacement at an authorized Miller service station.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in. INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT). Miller must be notified in writing within thirty (30) days of such defect or failure. MIGHT ARISE BY IMPLICATION. do not allow limitations of how long an implied warranty lasts. at Miller’s option: (1) repair. Co. Your distributor also gives you . BUT FOR THIS PROVISION. improperly operated or misused based upon industry standards.) 3 Years — Parts and Labor * * * * * * MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. but may vary from province to province. Wisconsin. every step of the way. The expertise of the distributor and Miller is there to help you. Miller’s option of repair or replacement will be F. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY. SPECIAL.. INDIRECT. Within the warranty periods listed below. 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.A. EXPRESS OR IMPLIED. contactors.S. Equipment that has been modified by any party other than Miller. WHETHER BASED ON CONTRACT. and other rights may be available. and to the extent that they may not be waived. or for a minimum of one year — whichever is greater. the exclusive remedies shall be. indirect. These items are covered by the manufacturer’s warranty. or.. Items furnished by Miller. the limitations and exclusions set out above may not apply. THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * 4. This Limited Warranty provides specific legal rights.

WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 www. 6/00 . An Illinois Tool Works Company 1635 West Spencer Street Appleton. Model Name Purchase Date Distributor Address City State Zip Serial/Style Number (Date which equipment was delivered to original customer.MillerWelds. Co. Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Miller Electric Mfg. File a claim for loss or damage during shipment. Co.Owner’s Record Please complete and retain with your personal records. PRINTED IN USA  2000 Miller Electric Mfg. Videos. 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.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.com Contact the Delivering Carrier for: For assistance in filing or settling claims.) For Service Call 1-800-4-A-Miller or see our website at www. contact your distributor and/or equipment manufacturer’s Transportation Department.

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