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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

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

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

Cutting And Welding Processes. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. STATIC (ESD) can damage PC boards. D Use proper static-proof bags and boxes to store. NY 10018. from American National Standards Institute. follow rated duty cycle. Locate welding operation 100 meters from any sensitive electronic equipment. and guards closed and securely in place. from Superintendent of Documents. Have the installation regularly checked and maintained. Arlington. 20402. or any metal when threading welding wire. D High-frequency (H. from National Fire Protection Association. stop using the equipment at once. Suite 501. Ontario. 1430 Broadway. H. keep spark gaps at correct setting. Be sure this welding machine is installed and grounded according to this manual.F. MA 02269.1-3. FALLING UNIT can cause injury. D Have only qualified persons familiar with electronic equipment perform this installation. from American Welding Society. Rexdale. D. move. OSHA 29 CFR 1910. Government Printing Office. VA 22202. Miami. Keep high-frequency source doors and panels tightly shut. Safe Handling of Compressed Gases in Cylinders. or shielding the work area. ANSI Standard Z49. or near combustible surfaces. 178 Rexdale Boulevard. If notified by the FCC about interference. close together. and down low. computers.S. D D D D OVERUSE can cause OVERHEATING D Allow cooling period. American Welding Society Standard AWS F4.2. Principal Safety Standards Safety in Welding and Cutting. D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Do not press gun trigger until instructed to do so. safety services. Operation. keep weld cables as short as possible. MOVING PARTS can cause injury. New York. CSA Standard W117.W. LeJeune Rd. over. OM-353 Page 3 . LeJeune Rd. RADIATION can cause interference. And Maintenance FIRE OR EXPLOSION hazard. or any other accessories. and protected to handle this unit. Washington. other people.) can interfere with radio navigation. NOT running gear. 1235 Jefferson Davis Highway. gas cylinders. D Do not overload building wiring – be sure power supply system is properly sized. or ship PC boards. and use grounding and shielding to minimize the possibility of interference. Quincy.1. be sure forks are long enough to extend beyond opposite side of unit. Quincy. rated.1. D D WELDING WIRE can cause injury. from American Welding Society. D D 1-4. 550 N. Additional Symbols For Installation.1. using line filters. the user must take extra measures such as moving the welding machine. D If using lift forks to move unit. using shielded cables. CGA Pamphlet P-1. D Keep all doors. Safe Practices For Occupation And Educational Eye And Face Protection. D Keep away from pinch points such as drive rolls. MOVING PARTS can cause injury. D Reduce current or reduce duty cycle before starting to weld again. 550 N. D Do not point gun toward any part of the body. Code for Safety in Welding and Cutting. from Canadian Standards Association. such as on the floor. covers. ANSI Standard Z87. U. D Use equipment of adequate capacity to lift and support unit. Miami FL 33126 Safety and Health Standards. Standards Sales. Canada M9W 1R3. NFPA Standard 51B. D Do not install unit near flammables. from Compressed Gas Association. D Keep away from moving parts. D Keep away from moving parts such as fans. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances. Batterymarch Park. D Be sure all equipment in the welding area is electromagnetically compatible. D Do not block or filter airflow to unit. To reduce possible interference.F. D Put on grounded wrist strap BEFORE handling boards or parts.W. NFPA Standard 70. from National Fire Protection Association. MA 02269.C. ARC WELDING can cause interference. and communications equipment. panels. If interference still occurs. D Do not install or place unit on. D Use lifting eye to lift unit only. Batterymarch Park. FL 33126 National Electrical Code.

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

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

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

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

178 Rexdale Boulevard.C. Cutting and Welding Processes. Il y a eu et il y a encore un certain souci à propos de tels champs. des études sont toujours en cours et les preuves continuent à être examinées. Rexdale (Ontario) Canada M9W 1R3. Afin de réduire les champs électromagnétiques dans l’environnement de travail. MA 02269. Batterymarch Park.W. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances. Miami FL 33126 Safety and Health Sandards. VA 22202. NY 10018.S. 1-5. norme CSA W117. norme ANSI Z49. après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans. causera des champs électromagnétiques. Quincy. de l’Association canadienne de normalisation. de l’American Welding Society. OM-353 Page 8 . il est alors recommandé de respecter les consignes ci–dessus. CGA Pamphlet P-1. de la Compressed Gas Association. coupage et procédés connexes. 550 N.2. D. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Batterymarch Park. Principales normes de sécurité Safety in Welding and Cutting. U. de la National Fire Protection Association. il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. pour l’organisme. de l’American Welding Society. Quincy. Suite 501. New York. Government Printing Office. des champs magnétiques basse fréquence Le courant de soudage. NFPA Standard 70. norme NFPA 51B. norme ANSI Z87. OSHA 29 CFR 1910. norme AWS F4. respecter les consignes suivantes : 1 2 3 4 5 Garder les câbles ensembles en les torsadant ou en les attachant avec du ruban adhésif. Cependant. MA 02269.1-4. Si vous êtes déclaré apte par votre docteur.1. Mettre tous les câbles du côté opposé de l’opérateur. Règles de sécurité en soudage. de la National Fire Protection Association. 1235 Jefferson Davis Highway.1. de l’American National Standards Institute. du Superintendent of Documents. 550 N.W. Arlington. Garder le poste de soudage et les câbles le plus loin possible de vous. Safe Handling of Compressed Gases in Cylinders. Safe Practices For Occupation And Educational Eye And Face Protection. 1430 Broadway. Toutefois. Miami FL 33126 National Electrical Code. un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves. n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. suivant le jugement du comité. Lejeune Rd. pendant son passage dans les câbles de soudage. vente de normes.1. Relier la pince de masse le plus près possible de la zone de soudure. 20402. Lejeune Rd. En attendant que les conclusions finales de la recherche soient établies. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets. Washington.

1 2.3 3. Do not remove or paint over (cover) the label. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols.2 3. Do not touch electrode with bare hand.2 2.SECTION 2 – DEFINITIONS 2-1.1 3. Wear dry insulating gloves. Become trained and read the instructions before working on the machine or welding.1 4 4.1 2. Wear complete body protection. Keep flammables away from welding.3 2. Protect yourself from electric shock by insulating yourself from work and ground. Do not weld on drums or any closed containers. Disconnect input plug or power before working on machine. Breathing welding fumes can be hazardous to your health.1 1. Have a fire extinguisher nearby and have a watch person ready to use it.1 3. 1 1. Use welding helmet with correct shade of filter. Welding sparks can cause explosion or fire. Arc rays can burn eyes and injure skin. Do not wear wet or damaged gloves.1 + 5 + + 6 5 6 + S-176 254-A OM-353 Page 9 .2 2.3 3. Use ear protection and button shirt collar. Keep your head out of the fumes. Don’t weld near flammables.3 4 4.1 Electric shock from welding electrode or wiring can kill.2 1.2 1. Welding sparks can cause fires. Use forced ventilation or local exhaust to remove the fumes.3 2 1 1. 1.2 3 3. Wear hat and safety glasses.3 3 2 2. Use ventilating fan to remove fumes.

4V 60% 100% U0 = 80V I2 U2 310A 200A 155A 22.2A I1Eff = 36A I1max = 63.2V 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 60% 100% 310A 200A 155A 32.4V 18V 16.2-2.4V 28V 26.2A I1Eff = 59A I1max = 72.2V X 25% 310A/22.2V X U0 = 80V I2 U2 25% 310A/32.2V 5A/20. Rating Label For CE Products 1 1 ISO/IEC 974-1 7A/10.

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 . Symbols And Definitions NOTE Some symbols are found only on CE products.2-3.

6*) 76 230 V 92 (4*) 66 460 V 46 (2*) 33 575 V 37 (1. Specifications Amperes Input at AC Balanced Rated Load Output.9*) 11 (11*) KW 8.2*) 34 (27*) 460 V 37 (2*) 24 (25*) 520 V 33 (1. Single-Phase PFC ** No PFC With PFC 200 V 85 (4.1 10/91 – SB-116 199 / SB-116 200 OM-353 Page 12 .5*) 48 (49*) 380 V 45 (2. A. 50/60 Hz. 40% Duty Cycle 200 V 106 (4. 50/60 Hz.6*) 80 V 21 S *While idling **Power Factor Correction 3-2.6*) 26 KVA 21 (0.3 (0.4 80 V 21 S *While idling **Power Factor Correction Rated Welding Output NEMA Class I (60) – 200 Amperes. 28 Volts AC.89*) 15.6*) 19 (20*) KVA 17 (0.SECTION 3 – INSTALLATION 3-1.4 (0. 60% Duty Cycle Amperes Input at AC Balanced Rated Load Output. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source.3 (0. Single-Phase PFC** No PFC With PFC Rated Welding Output NEMA Class II (40) – 250 Amperes.8*) 48 (49*) 575 V 30 (1. DC Mode B.4*) 37 (30*) 415 V 41 (2. AC Mode ssb1.68*) Amp Range Max OCV IP Rating 5–310 A 11.2 KW 11.2*) 64 (51*) 230 V 74 (4*) 48 (49*) 260 V 65 (3. Curves of other settings fall between the curves shown.6*) 55 (57*) 220 V 77 (4. 30 Volts AC.7*) Amp Range Max OCV IP Rating 5–310 A 8.

light goes on (CE models only). 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 . and cooling fan runs. output stops. If unit overheats. Reduce amperage or duty cycle before welding. thermostat opens. Y Exceeding duty cycle can damage unit and void warranty.3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Wait fifteen minutes for unit to cool.

See Section 2-2) Use rating label to determine input power needs. Movement 1 If using lifting forks. extend forks beyond opposite side of unit. Selecting A Location 1 2 Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit.3-4. 5 6 Plate Label (CE Models Only) Line Disconnect Device Location And Airflow 6 Locate unit near correct input power supply. 3 4 OR 2 Rating Label (Non CE Models Only) Rating Label (CE Models Only. 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 . 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. CE label located on rear panel.

Tipping Y Be careful when placing or moving unit over uneven surfaces. If interference still occurs. 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. keep weld cables as short as possible. 3-7. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. and down low. such as on the floor.3-6. using shielded cables. close together. using line filters. Contact your distributor for the mm2 equivalent weld cable sizes. Be sure this welding machine is installed and grounded according to this manual. or shielding the work area. Locate welding operation 100 meters from any sensitive electronic equipment. To reduce possible interference. S-0007-E OM-353 Page 15 . the user must take extra measures such as moving the welding machine.

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

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 .3-10.

Placing Jumper Links And Connecting Input Power Check input voltage available at site. check rating label (see Section 3-4) for allowable input voltages. Do not make connections for any other voltages. Y Only make connections for the voltages shown on the label inside your unit. Reinstall side panel.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. 7/16 in ST-117 263-K OM-353 Page 18 . 1/2. 1 200 VOLTS 230 VOLTS 460 VOLTS Jumper Link Label Check label inside your unit– only one label is on unit. 2 Jumper Links Move jumper links to match input voltage. If jumper link label is missing from inside unit. 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. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20.

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

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

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

When the control is in the Balanced position.5mm) of etched zone along the weld toes is required. AC Balance Control 1 AC Balance Control Balance Control (AC GTAW): Control changes the AC output square wave. only a minimal amount.10 in (2. Rotating the control towards 0 provides more cleaning action of the workpiece. 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. the wave shape provides equal penetration and cleaning action. process variables.4-6. Rotating the control towards 10 provides deeper penetration. To produce a good weld. Joint configuration. and oxide thickness may affect setting. Set control to 7 and adjust as necessary. set-up. may help to restabilize the arc. If this condition occurs. S-0795-A OM-353 Page 22 . increasing the Balance control towards maximum penetration. excess cleaning is not necessary. approximately a 0. Application: When welding on oxide forming materials such as aluminum or magnesium. Arc rectification can occur when welding above 200 amps and/or while welding with helium gas.

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

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

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

During Heavy Service.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. and gas flow stop. high frequency. 1 CB1 Ref. Press button to reset breaker. Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens. Clean Monthly OR 5-2. ST-154 795-C OM-353 Page 26 . Routine Maintenance Y Disconnect power before maintaining. output to the 115 volts ac duplex receptacle.

proceed as follows: 3 Adjustment Screws Loosen screws. Check. Open access door. OM-353 Page 27 .203 mm). place Output (Contactor) switch in On position. repair. No weld output. 1 4 4 Tungsten End Of Point Replace point if tungsten end disappears. if necessary (see Section 3-11). If adjustment is needed. Tighten screws to 12 in/lbs torque (overtightening will deform plastic base). Remedy Place line disconnect switch in On position (see Section 3-11). Check and replace line fuse(s).008 in (0. unit on. Check for proper input power connections (see Section 3-11). Adjusting Spark Gaps Y Turn Off power before adjusting spark gaps. If using remote control. 2 3 3 2 1 Spark Gap Normal spark gap is 0. Tools Needed: Ref. Adjust other gap. Unit overheated.5-3. Allow unit to cool with fan On (see Section 3-3). Troubleshooting Trouble No weld output. unit completely inoperative. Have Factory Authorized Service Agent check control board PC1. If remote is not being used. Check for proper jumper link position (see Section 3-11). or replace remote control. Close access door. Place gauge of proper thickness in spark gap. 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap. ST-154 795-C 5-4. place Output switch in Remote 14 position. and make sure remote control is connected to Remote 14 receptacle. do not clean or dress tungsten.

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

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

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 .SECTION 6 – HIGH FREQUENCY (HF) 6-1. 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. 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.

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

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

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

Panel. 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.. Hardware is common and 8 9 10 not available unless listed. Front w/Components OM-353 Page 34 .

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

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

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

Control Panel. 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.. Hardware is common and not available unless listed. Lower Front OM-353 Page 38 .

. . . . . . . . . 15 . . . . . str dx grd 15A 125V . . . . . Dia. . . . . . . . . . . . . . . .. . . . . . . . .. .. . . front lower . . . . . . . . . . . . . . .. . . . .. . . polyp met film . C6 . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . PLG4 . . . . ... 16 . . . . . .. . . . . . . .. . . .. . . . . . . . . . . . . .. . polyp met film . . . 21 . . . . . . . . . . . .. . POINT. 7 . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . OM-353 Page 39 . . . . . .. 18 . . . . . . . . . . . . .. . . . . . . . . . . . SPARK GAP ASSEMBLY (consisting of) . . . . . CAPACITOR. . . . . . . . C3 . CAPACITOR . .. Mkgs.Item No. . . .. . . . .00L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . .. . . . .3K .5 ohm . . . . . . . .. . . . . . . . .. . . . . . . . 3 ..01uf 500VDC . .. .. . .. . . . . . . . . . .. CIRCUIT BREAKER. . . . R25 . . . . . . . G . . .. . 23 . . . . . . . . . . . . . . . . . . GS1 . . . . . . . . . CAPACITOR. . 1 . . . . . . .002uf 10. . . . . . . . .. . . . spark gap . . . . . . . . .. . . . man reset 1P 15A 250VDC . . . . pwr output . . . . . . RHEOSTAT. . . . w/fitting and leads (consisting of) . . . . . . . . . . .. . . . . . . . . 19 . . . . . . . .. . . . . . . . . . . . . . BASE. . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . Part No. . . . . . . . . . . . . . . . . . . . . .. . .. . CAPACITOR. . . . . . . .. . . .. . . . . high voltage 115V . . . . .. . . .. . . . . . . . . . . . spark gap . . . . . . . . . . . . . . mica . . . . . . WW 25W 1. . . . . . . . . PLG3 . . . . FITTING. T2 .. . . COIL. . . . . . . CONNECTOR & SOCKETS . . . . .. . T3 . . . . . . . . . . . . . . . . . . . . 8 . . .. . .. . .. . . . . . . . . . . . . . . . . . .000V panel mtg (CE Models Only) .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . cer disc . 2 . . . . . . . . . . . . . . . . . . 22 . . . BRACKET. . . . . . . . . C4 . . . . . . .. . . . . . . . . . RC1 .. . . . . . . . . . . . . . . .. . . . . . . 4 . . . . TRANSFORMER. . . . . 5 . . . . . . . . . . . . . RC2 . mounting components . . pipe brs elbow 1/4NPT x . . . . .. . . . .. . . . . . . . . PC2. . . .. . . . . . . . . . . . .. . . . . . HOLDER.. ... . . . . . . . . . . . .. . . . . . . . . pointer . . .. . . . . .. . . . . . . . . 16 . . . . . . speed 1. TERMINAL. CONNECTOR & SOCKETS .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .. .. . . . . door access HF . . . . . Control Panel. . . . . .. . .625-18R . . . . . .. . . .. . 11 . . . . . . . . .. . . . . . polyp film . . . . . . . . . . . . HF coupling . . . . . . . PANEL. .. KNOB.250 ID w/set screw . . . . . . . . . . . . . .. . VALVE. . . 20 . . . . . . . . .. CB1 . . .. . . . . . . . . . . . . . C4 . . . . . . . . . . . . . . . . . . . . .. . . 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. VALVE. . . . . . . . . . . . . . . . . . . . . . . .. 14 . . . C14 . . . .. . . . .. . . . .. . .05uf 500 VDC . . . . . . . .. . . . . . . . .. . . . 115VAC 2 way . Description Figure 7-6. . . . . . . . . . . . . .. . . . . . . . . . 6 . . . . . . . . . C15 . . . . . . . . . . . RECEPTACLE. RESISTOR ASSEMBLY. . . . . . . . . . . . . CIRCUIT CARD ASSEMBLY . . . . . . . . . . . . . . . . ... .. .... . . . . . . . . . . . . . . . PLG21 . . . . . . . .. . . . R13 . w/leads . . CONNECTOR & SOCKETS . . . . . Model and serial number required when ordering parts from your local distributor. .. . . . R8 . .002uf 4400VAC panel mtg . . . . . . . . . . . . . .. . . . . . . . . .. Lower Front (Fig 7-2 Item 18) Quantity . . . .. . . . . . . . . .. . . use only Manufacturer’s Suggested Replacement Parts. . . . .875dia x . . . . . .. PANEL. . . . . . . CAPACITOR.. . . . . .. . . . . . . . . . .. . . . . . points . . . .. . .. . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR. . 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 . . . NUT. . . . 9 .. C2 W 3. . . . . . . . . . . . . . . . . . RESISTOR. .. . .

Notes OM-353 Page 40 .

.

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. This Limited Warranty provides specific legal rights.) 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. Miller’s option of repair or replacement will be F. TORT OR ANY OTHER LEGAL THEORY.. 6 Months — Batteries 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets . ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY. GUARANTY OR REPRESENTATION AS TO PERFORMANCE. slip rings. TO THE EXTENT PERMITTED BY LAW.O. at Miller’s option: (1) repair. cutting nozzles. and other rights may be available. Within the warranty periods listed below. do not allow limitations of how long an implied warranty lasts. and other rights may be available. but manufactured by others. Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Items furnished by Miller. such as engines or trade accessories. * * 2. INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE. Miller Electric Mfg.O. Consumable components. but may vary from province to province. CUSTOM OF TRADE OR COURSE OF DEALING. brushes. Service You always get the fast. 3. EXPRESS OR IMPLIED. THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. BUT FOR THIS PROVISION. (3) the reasonable cost of repair or replacement at an authorized Miller service station. relays or parts that fail due to normal wear. Wisconsin. AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH. 5. Equipment that has been modified by any party other than Miller. In the event of a warranty claim covered by this warranty.. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser. the exclusive remedies shall be. 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * 4. so the above limitation or exclusion may not apply to you. contactors. Factory at Appleton.S. or equipment which has not had reasonable and necessary maintenance. Co. Some states in the U. 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. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. This warranty provides specific legal rights. such as contact tips. 1.A. or the exclusion of incidental. improperly operated or misused based upon industry standards. indirect. In Canada. or equipment that has been improperly installed. 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. at a Miller authorized service facility as determined by Miller. 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. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. INDIRECT. WHETHER BASED ON CONTRACT.) 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. 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. or equipment which has been used for operation outside of the specifications for the equipment. Your distributor also gives you . * * * * * * APT. but may vary from state to state. These items are covered by the manufacturer’s warranty. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. reliable response you need. and to the extent that they may not be waived. SPECIAL. INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT).B. at which time Miller will provide instructions on the warranty claim procedures to be followed. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT. MIGHT ARISE BY IMPLICATION. special or consequential damages. Support Need fast answers to the tough welding questions? Contact your distributor. 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.B. the limitations and exclusions set out above may not apply. The expertise of the distributor and Miller is there to help you. miller_warr 7/00 3. Miller must be notified in writing within thirty (30) days of such defect or failure. legislation in some provinces provides for certain additional warranties or remedies other than as stated herein. or (2) replacement. Appleton. 5 Years Parts – 3 Years Labor Call 1-800-4-A-MILLER for your local Miller distributor. or for a minimum of one year — whichever is greater. 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. where authorized in writing by Miller in appropriate cases. every step of the way. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. OPERATION OF LAW. WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.. if any. LIMITED WARRANTY – Subject to the terms and conditions below. 2. or.Effective January 1. or F. Wisconsin. Most replacement parts can be in your hands in 24 hours.

Always provide Model Name and Serial/Style Number. An Illinois Tool Works Company 1635 West Spencer Street Appleton.MillerWelds.MillerWelds. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools. Co. contact your distributor and/or equipment manufacturer’s Transportation Department.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. 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.Owner’s Record Please complete and retain with your personal records. Co. 6/00 .com Contact the Delivering Carrier for: For assistance in filing or settling claims. File a claim for loss or damage during shipment.) For Service Call 1-800-4-A-Miller or see our website at www. PRINTED IN USA  2000 Miller Electric Mfg. Videos. Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Miller Electric Mfg. Model Name Purchase Date Distributor Address City State Zip Serial/Style Number (Date which equipment was delivered to original customer.