OM-2233
203 409Q
2007−04
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/Autoline
R
Arc Welding Power Source
R
Maxstar 200 STR
And Non-CE Models
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
5
5
7
8
8
3-2. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-7. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-8. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-2. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-3. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-4. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-6. DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-3. Troubleshooting Help Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 8 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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TABLE OF CONTENTS
SECTION 10 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-1. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-2. Electrode and Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10-3. Striking an Arc − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10-4. Striking an Arc − Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10-5. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10-8. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-9. Electrode Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10-10. Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10-11. Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10-12. Tee Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10-13. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-14. Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-15. Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-16. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10-17. Troubleshooting − Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10-18. Troubleshooting − Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10-19. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-20. Troubleshooting − Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10-21. Troubleshooting − Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
R
Maxstar 200 STR
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(December 1996 − 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
dec_stat_6/05
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Notes
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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Marks a special safety message.
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1-2. Arc Welding Hazards
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
Safety Standards.
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Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
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D
Y
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Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
During operation, keep everybody, especially children, away.
D
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
D
D
FUMES AND GASES can be hazardous.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
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If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
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Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
OM-2233 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D
Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
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Wear approved safety glasses with side shields under your
helmet.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
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Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
NOISE can damage hearing.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
damagehearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Wear approved ear protection if noise level is
high.
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D
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
CYLINDERS can explode if damaged.
D
D
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
D
D
Do not use welder to thaw frozen pipes.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D
D
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
D
D
Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
D
OM-2233 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
D
D
Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
D
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
D
Read Owner’s Manual before using or servic-
ing unit.
D
Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
D
D
Do not block or filter airflow to unit.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
STATIC (ESD) can damage PC boards.
D
D
Have the installation regularly checked and maintained.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
D
Do not press gun trigger until instructed to do
so.
Be sure this welding machine is installed and grounded
according to this manual.
D
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-2233 Page 3
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1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101(phone: 617−770−3000, website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2233 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som _3/05
Y
Avertissement: se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
Symbole graphique d’avertissement ! Attention ! Cette pro-
cédure comporte des risques possibles ! Les dangers éven-
tuels sont représentés par les symboles graphiques joints.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Y
Indique un message de sécurité particulier
.
S
i
g
n
i
f
i
e
N
O
T
E
;
n
’
e
s
t
p
a
s
r
e
l
a
t
i
f
à
l
a
s
é
c
u
r
i
t
é
.
2-2. Dangers relatifs au soudage à l’arc
Y
Les symboles représentés ci-dessous sont utilisés dans ce manuel
pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions en
matière de sécurité indiquées ci-dessous ne constituent qu’un
sommaire des instructions de sécurité plus complètes fournies
observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonction-
ner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les per-
sonnes, notamment les enfants de l’appareil.
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement en
place.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
D
D
D
D
Y
Y
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
D
D
D
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
D
D
Ne pas toucher aux pièces électriques sous tension.
Porter des gants isolants et des vêtements de protection secs et sans
trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou des
tapis assez grands afin d’éviter tout contact physique avec la pièce à
couper ou le sol.
Ne pas se servir de source électrique à courant électrique dans les zo-
nes humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère né-
cessaire, se servir de la fonction de télécommande si l’appareil en est
équipé.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
D
D
Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions indi-
quées dans la partie Entretien avant de toucher les pièces.
D
D
D
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereuse pour la santé.
D
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si l’on
porte des vêtements mouillés ; sur des structures métalliques telles que
sols, grilles ou échafaudages ; en position coincée comme assise, à ge-
noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC
à tension constante (à fil), 2) un poste à souder DC manuel (électrode)
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des
situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer le poste correctement et le mettre à la terre convenablement
selon les consignes du manuel de l’opérateur et les normes nationales,
provinciales et locales.
D
D
D
D
Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-
peurs.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu-
vé.
Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un sur-
veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-
quant des blessures ou des accidents mortels. S’assurer que l’air de
respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz haute-
ment toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-
vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
portant un respirateur à alimentation d’air. Les revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxi-
ques en cas de soudage.
D
D
D
D
D
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
OM-2233 Page 5
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LES RAYONS D’ARC peuvent entraî-
ner des brûlures aux yeux et à la peau.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-
quer des brûlures dans les yeux et sur la peau.
D
Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D
Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
d’air homologué.
Des étincelles sont projetées pendant le soudage.
D
Porter un casque de soudage approuvé muni de verres filtrants ap-
proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous vo-
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
tre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
D
Ne pas toucher des parties chaudes à mains
nues.
D
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D
D
Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
Porteurs de stimulateur cardiaque, rester
à distance.
d’étincelles,des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrodeavec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
D
Les porteurs d’un stimulateur cardiaque doi-
vent d’abord consulter leur médecin avant de
s’approcherdes opérations de soudage à l’arc,
de gougeage ou de soudage par points.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi-
gneusementavec des protections homologuées.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa-
rés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une longue
distance par des chemins inconnus éventuels en provoquant des
risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
En cas de non-utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
D
D
D
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de soudage,
les manipuler avec précaution.
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
ve, des chocs mécaniques, des dommages physiques, du lai-
tier, des flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support sta-
tionnaireou dans un porte-bouteilles pour les empêcher de tom-
ber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
D
D
D
D
D
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
D
Avant de souder, retirer toute substance combustible de ses poches
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
telles qu’un allumeur au butane ou des allumettes.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifi-
que ; les maintenir ainsi que les éléments associés en bon état.
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
Le couvercle du détendeur doit toujours être en place, sauf lors-
que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
Utiliser les équipements corrects, les bonnes procédures et suf-
fisammentde personnes pour soulever et déplacer les bouteil-
les.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécuri-
té.
Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un ex-
tincteur à proximité.
D
D
DES
PARTICULES
VOLANTES
peuvent blesser les yeux.
D
Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage
génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D
D
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
OM-2233 Page 6
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Ne pas installer l’appareil à proximité de
produits inflammables.
D
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
D
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D
Lire le manuel d’utilisation avant d’utiliser ou
d’intervenirsur l’appareil.
D
D
Utiliser uniquement des pièces de rechange
Miller/Hobart.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
D
Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipe-
ments de radio-navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
D
D
Prévoir une période de refroidissement ;
respecter le cycle opératoire nominal.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’instal-
lation.
L’utilisateurest tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenirsoigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
distance correcte et utiliser une terre et un blindage pour réduire
les interférences éventuelles.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Veiller à ce que tout l’équipement de la zone de
D
Ne pas s’approcher des organes mobiles.
soudage soit compatible électromagnétiquement.
D
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
ment électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentaires telles que le déplacement du poste, l’utilisation de
câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en enga-
geant le fil de soudage.
2-4. Proposition californienne 65 Avertissements
Y
Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :
fumées et des gaz qui contiennent des produits chimiques dont
Y
Les gaz d’échappement des moteurs contiennent des produits
l’État de Californie reconnaît qu’ils provoquent des malformations
congénitales et, dans certains cas, des cancers. (Code de santé et
de sécurité de Californie, chapitre 25249.5 et suivants)
chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres pro-
blèmes de procréation.
Pour les moteurs diesel :
Y
Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des can-
cers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Y
Les gaz d’échappement des moteurs diesel et certains de leurs
composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou au-
tres problèmes de procréation.
OM-2233 Page 7
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2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone
:
:
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou
à
Toronto 416-747-4044, site Internet
ternet : www.global.ihs.com).
www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000,site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101(téléphone : 617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220,site Internet : www.osha.gov).
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
champs magnétiques et électriques.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
Le courant de soudage, pendant son passage dans les câbles de souda-
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
certain souci à propos de tels champs. Cependant, après avoir examiné
votre corps.
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
4. Garder le poste de soudage et les câbles le plus loin possible de
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
vous.
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ».
5. Connecter la pince sur la pièce aussi près que possible de la sou-
Toutefois, des études sont toujours en cours et les preuves continuent à
dure.
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-
les procédures suivantes :
cin approuve, il est recommandé de suivre les procédures précédentes.
OM-2233 Page 8
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SECTION 3 − DEFINITIONS (CE Models)
3-1. Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
2
Breathing welding fumes can be
hazardous to your health.
3.3 Do not weld on drums or any closed
containers.
2.1 Keep your head out of the fumes.
4
Arc rays can burn eyes and injure
skin.
1
Electric shock from welding electrode
or wiring can kill.
2.2 Use forced ventilation or local exhaust
to remove the fumes.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
2.3 Use ventilating fan to remove fumes.
3
Welding sparks can cause explosion
or fire.
1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.
5
Become trained and read the
instructions before working on the
machine or welding.
3.1 Keep flammables away from welding.
Do not weld near flammables.
3.2 Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
1.3 Disconnect input plug or power before
working on machine.
6
Do not remove or paint over (cover)
the label.
4
4.1
1
1.1
1.2
1.3
2
2.1
3.1
2.2
2.3
5
3
3.2
3.3
6
179 310-A
OM-2233 Page 9
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Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
Electric shock from wiring can
kill.
2
Disconnect input plug or
power before working on
machine.
1
2
4
5
3
3
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
V
4
5
6
7
Always wait 60 seconds after
power is turned off before
working on unit, OR
V
> 60 s
V
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
S-185 836
9
8
6
7
8
9
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
1
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2
3
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
°
∠ = <60
∠
4
5
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309-A
2
5
3
4
1/96
3-2. WEEE Label (For Products Sold Within The EU)
Do not discard product (where ap-
plicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
OM-2233 Page 10
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3-3. Manufacturer’s Rating Label
.
S
e
e
f
o
r
f1
f2
EN 60974−1
location.
1A 10V
200A 18V
U
=115V
1
. Use rating label to de-
termine input power
requirements.
100%
150
16
100%
X
40%
200
18
60%
175
17
70%
I2
125
15
150
16
S
U
U
2
80V
o
1A 20V
200A 28V
U
=115V
1
100%
125
25
80%
100
24
X
40%
175
27
60%
150
26
50%
I2
125
25
S
U
U
2
80V
o
I1 max
I1 eff
50/60 Hz
50/60 Hz
50/60 Hz
U
U
U
=115V
35
31
19
25
17
11
1
1
3
1
=230V
=230V
1
1
50/60 Hz
50/60 Hz
U
U
=400V
=460V
IP23
11
9
6
5
3
3
1
1
195 646-B
3-4. Symbols And Definitions
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Amperes
High Temperature
Voltage Input
A
3 Phase Static Frequency
Converter-Transformer-Rectifier
Volts
V
Lift-Arc Start
Percent
Arc Force (DIG)
Remote
(GTAW)
Seconds
Negative
Protective Earth
(Ground)
Alternating
Current
Rated Welding
Current
I2
S
On
Off
Positive
Conventional Load
Voltage
Duty Cycle
Direct Current
Line Connection
U2
X
Degree Of
Protection
Rated Maximum
Supply Current
Maximum Effective
Supply Current
Primary Voltage
U1
IP
I1max
S
I1eff
Suitable For Areas
Of Increased
Shock Hazard
Rated No Load
Voltage (Average)
Increase/Decrease
Of Quantity
Hertz
U0
Hz
Output
Adjust
OM-2233 Page 11
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SECTION 4 − INSTALLATION
4-1. Specifications
Amperes Input At Rated Output, 50/60Hz
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
Input Power
Rated Output
KVA
KW
115
230
400
460
80∇
9-14♦
Three-Phase
Stick Process
150 A @ 26 VDC,
60% Duty Cycle
13.1
7.4
6.4
5.2
5.0
1 − 200
1 − 200
1 − 200
1 − 200
1 − 200
1 − 200
-−
0.16*
0.24*
0.25*
0.06* 0.03*
80
Three-Phase
TIG Process
10.5
6.0
5.2
4.2
4.0
175 A @ 17 VDC,
60% Duty Cycle
-−
0.16*
0.24*
0.25*
0.06* 0.03*
9-14♦
80∇
9-14♦
18.4
10.3
8.9
7.3
7.0
Three-Phase
Stick Process
200 A @ 28 VDC,
30% Duty Cycle
0.16*
0.24*
0.25*
0.06* 0.03*
80
12.7
7.2
6.2
5.1
4.9
Three-Phase
TIG Process
200 A @ 18 VDC,
40% Duty Cycle
0.16*
0.24*
0.25*
0.06* 0.03*
9-14♦
80∇
9-14♦
Single-Phase
Stick Process
10.6
.25*
150 A @ 26 VDC,
60% Duty Cycle
21.7
0.23*
5.0
5.0
-−
-−
0.05* 0.02*
80
Single-Phase
TIG Process
17.4
8.5
4.0
4.0
175 A @ 17 VDC,
60% Duty Cycle
-−
-−
0.23*
.25*
0.05* 0.02*
9-14♦
80∇
9-14♦
Single-Phase
Stick Process
125 A @ 25 VDC,
50% Duty Cycle
34.1
0.42*
4.0
3.8
-−
1 − 200
-−
-−
0.05* 0.03*
80
Single-Phase
TIG Process
3.4
3.4
150 A @ 16 VDC,
70% Duty Cycle
29.7
0.42*
-−
1 − 200
-−
-−
0.05* 0.03*
9-14♦
80∇
9-14♦
Single-Phase
Stick Process
3.2
3.2
100 A @ 24 VDC,
80% Duty Cycle
28.1
0.42*
1 − 200
-−
-−
-−
0.05* 0.03*
80
Single-Phase
TIG Process
2.6
2.6
125 A @ 15 VDC,
100% Duty Cycle
23.0
0.42*
1 − 200
-−
-−
-−
0.05* 0.03*
9-14♦
*While idling
♦Low open-circuit voltage while in Lift-Arc
t
on all models, and Stick on models with stock numbers 907 036 and 907 037.
∇Normal open-circuit voltage (80 volts) is present while in the Stick process for models with stock number 907 220.
NOTE: Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.
NOTE: This unit is equipped with Auto-Linet. The Auto-Line circuitry automatically connects to 120−460 VAC, single- or three-phase power without
removing the cover to relink the power source.
OM-2233 Page 12
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4-2. Volt-Ampere Curves
Volt-amperecurves show minimum
and maximum voltage and amper-
age output capabilities of welding
power source. Curves of other set-
tings fall between curves shown.
115V A C In p u t
140
120
Stick Max
TIG Max
100
80
60
40
20
0
Stick/TIG Min
DIG Max
0
50
100
150
200
250
Amperes
O th er In p u t V o ltag es
140
120
100
80
Stick Max
TIG Max
60
40
Stick/TIG Min
DIG Max
.
20
0
0
50
100
150
200
250
Amperes
*Amperage setting must be reduced to obtain currents less than highlighted data* point.
189 767-A
OM-2233 Page 13
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4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, and
cooling fan runs. Wait fifteen min-
utes for unit to cool. Reduce amper-
age or duty cycle before welding.
Y
Exceeding duty cycle can
damage unit and void
warranty.
90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process
125 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process
150 A @ 60% Duty Cycle For Stick Process (Other Voltages)
175 A @ 60% Duty Cycle For TIG Process (Other Voltages)
6 Minutes Welding
4 Minutes Resting
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
189 770-A
OM-2233 Page 14
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4-4. Selecting A Location
1
2
3
IdentificationPlate
Rating Label
Line Disconnect Device
Dimensions And Weight
34.7 lb (15.7 kg) - without power cord
37.3 lb (16.9 kg) - with power cord
Locate unit near correct input
power supply.
Y
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
17-1/4 in
(438 mm)
13-3/8 in
(333 mm)
7-9/16 in
(192 mm)
1
Location And Airflow
3
2
18 in
(460 mm)
18 in
(460 mm)
802 886-A
OM-2233 Page 15
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4-5. Weld Output Terminals And Selecting Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding
150 ft
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y
Y
Turn off power before
connectingto weld out-
put terminals.
10 − 60% 60 − 100%
Welding
Amperes***
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
+
−
Output Receptacles
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
2
( ) = mm for metric use
***Select weld cable size for pulsing application at peak amperage value.
S-0007-E−
4-6. Remote 14 Receptacle Information
A
J
K
Socket*
Socket Information
I
B
C
L
N
H
M
D
G
C
Output to remote control; 0 to +10 volts dc output
to remote control.
F
E
D
E
Remote control circuit common.
REMOTE
OUTPUT
CONTROL
0 to +10 volts dc input command signal from
remote control.
ST-802 541
K
Chassis common.
CHASSIS
*The remaining sockets are not used.
OM-2233 Page 16
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4-7. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections
Y
Turn off power before mak-
ing connections.
1
Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4
5
2
Negative (−) Weld Output
Terminal
6
Connect TIG torch to negative weld
output terminal.
3
3
4
Gas Cylinder
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5
6
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas hose to regula-
tor/flowmeter.
1
7
Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.
2
7
Tools Needed:
11/16 in, 1-1/8 in, (21 mm)
Ref. 802 888-A
OM-2233 Page 17
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4-8. Stick DCEP (Direct Current Electrode Positive) Connections
Y
Turn off power before mak-
ing connections.
1
Negative (−) Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2
Positive (+) Weld Output
Terminal
Connect electrode holder to posi-
tive weld output terminal.
2
1
Ref. 802 888-A
4-9. Electrical Service Guide
Actual input voltage cannot exceed - 10% of minimum or +10% of maximum input
voltages indicated in table.
NOTE
Single-Phase,
100% Duty
Cycle
Single-Phase,
60% Duty
Cycle
Three-Phase, 60% Duty
Cycle
Input Voltage
115
25
230
22
230
400
7.4
460
6.4
Input Amperes At Rated Output
13.1
1
2
Max Recommended Standard Fuse Rating In Amperes
Time Delay
25
35
10
25
30
12
15
20
14
8
8
3
Normal Operating
10
14
10
14
4
Min Input Conductor Size In AWG
102
(31)
308
(94)
407
Max Recommended Input Conductor Length In Feet (Meters)
57 (17)
10
79 (24)
12
(124)
4
Min Grounding Conductor Size In AWG
14
14
14
Reference: 2005 National Electrical Code (NEC)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-2233 Page 18
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4-10. Connecting Input Power
A. Connecting Three-Phase Input Power
Y
Y
Y
Installationmust meet all National
and Local Codes − have only quali-
fied persons make this installation.
3
Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
= GND/PE Earth Ground
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4
. The Auto-Line circuitry in this unit au-
tomatically adapts the power source
to the primary voltage being applied.
Check input voltage available at site.
This unit can be connected to any in-
put power between 120 and 460 VAC
without removing cover to relink the
power source.
7
For Three-Phase Operation
2
1
2
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
3
4
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
L1
5
6
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
3
5
L2
L3
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
6
1
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7
Over-Current Protection
Select type and size of over-current
connect switch shown).
Close and secure door on disconnect de-
vice. Remove lockout/tagout device, and
place switch in the On position.
Tools Needed:
2/04 - Ref. 802 136-A
OM-2233 Page 19
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B. Connecting Single-Phase Input Power
Y
Y
Y
Installationmust meet all National
and Local Codes − have only quali-
fied persons make this installation.
Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
1
. The Auto-Line circuitry in this unit au-
tomatically adapts the power source
to the primary voltage being applied.
Check input voltage available at site.
This unit can be connected to any in-
put power between 120 and 460 VAC
without removing cover to relink the
power source.
8
=GND/PE Earth Ground
10
7
9
1
Black And White Input Conductor
(L1 And L2)
2
3
Red Input Conductor
Green Or Green/Yellow Grounding
Conductor
L1
L2
4
5
Insulation Sleeving
Electrical Tape
1
3
Insulate and isolate red conductor as
shown.
1
6
7
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
6
2
8
Disconnect Device Grounding
Terminal
3
9
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
6
5
4
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
connect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
2/04 - Ref. 802 136-A
Tools Needed:
OM-2233 Page 20
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SECTION 5 − OPERATION
5-1. Controls
A. Non CE Units
5
2
4
3
1
6
NOTE:Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
3
DIG Control
High Temperature Shutdown Light
5
Power On/Troubleshooting Help Aids
Light
1
Process Controls
Amperage Control
Power Switch
6
4
2
Use switch to turn unit and indicator light
On/Off.
202 323-B / 802 889
OM-2233 Page 21
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B. For CE Units
5
4
2
3
1
6
NOTE:Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
3
DIG Control
5
Power On/Troubleshooting Help Aids
Light
High Temperature Shutdown Light
1
Process Controls
Amperage Control
Power Switch
6
4
2
Use switch to turn unit and indicator light
On/Off.
202 722-A / 802 889
OM-2233 Page 22
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5-2. Process Control
1
Process Control
CE Model
Rotate knob up to select the Stick
process. Rotate knob down to se-
lect the TIG Lift Arc process.
Stick (SMAW) - This is a DCEP (di-
rect current electrode positive) pro-
cess. Make connections according
1
1
TIG Lift-Arct - This is a DCEN (di-
rect current electrode negative)
process in which the electrode
must come in contact with the work
piece to initiate an arc (see Section
5-3). Make connections according
5-3. Lift-Arc™ Start Procedure
Lift-Arc Start
With Lift-Arct selected, start arc
as follows:
1
2
TIG Electrode
Workpiece
Turn gas on. Touch tungsten elec-
trode to workpiece at weld start
point. Hold electrode to work-
piece for 1-2 seconds, and slowly
lift electrode. Arc is formed when
electrode is lifted.
Lift-Arc Start Method
1
2
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
1 − 2
“Touch”
Seconds
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to re-
place the scratch method.
Do NOT Strike Like A Match!
OM-2233 Page 23
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5-4. Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as follows:
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece like strik-
ing a match; lift electrode slightly after touch-
ing work. If arc goes out electrode was lifted
to high. If electrode sticks to workpiece, use
a quick twist to free it.
1
Y
For models with stock number 907
220, normal open-circuit voltage (80
volts) is present before electrode
touches workpiece.
2
For models with stock numbers 907 036 and
907 037, normal open-circuit voltage is not
present before electrode touches work-
piece; only a low sensing voltage is present
between electrode and workpiece.
3
5-5. Amperage Control
1
A (Amperage Control)
CE Model
Rotate knob clockwise to increase
amperage (Min-200 amps).
1
1
Min
Min
5-6. DIG Control
1
DIG Control
CE Model
1
1
Control increases SMAW short-cir-
cuit amperage at low arc voltage.
This allows the operator to use a
very short arc length without stick-
ing the electrode.
Set control at 0 for normal welding
amperage. Turn clockwise to in-
crease short-circuit amperage.
OM-2233 Page 24
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SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
Y
Disconnect power before maintaining.
.
M
a
i
n
t
a
i
n
m
o
r
e
o
f
t
e
n
d
u
r
i
n
g
s
e
v
e
r
e
c
o
n
d
i
t
i
o
n
s
.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals.
Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Y
Do not remove case when
blowing out inside of unit
Blow out inside. During
heavy service clean
monthly.
6-2. Blowing Out Inside Of Unit
Y
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
802 886-A
OM-2233 Page 25
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6-3. Troubleshooting Help Aids
1
2
stays on.
will continue when the unit has cooled.
. All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
Help 0 Display
Help 4 Display
Indicates a short in the thermal protection
circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this happens.
1
2
Output LED
Indicates an open in the thermal protection
circuitry located on the top heat sink. Con-
tact a Factory Authorized Service Agent if
this happens.
High Temperature LED
The Output LED turns on when power is
turned on. The LED is also used to indicate
several machine malfunctions. When one
of the malfunctions listed below occurs, the
LED will first turn off for 1.5 seconds, and
then it will begin to blink. The number of
blinks corresponds to a Help message re-
lating to that malfunction. After the LED
blinks the appropriate number of times, the
LED will again turn off for 1.5 seconds, and
the sequence will start again.
Help 1 Display
Help 5 Display
Indicates a malfunction in the primary pow-
er circuit caused by an overcurrent condi-
tion in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this happens.
Indicates the top heat sink has overheated.
The unit has shut down to allow the fan to
tinue when the unit has cooled.
Help 8 Display
Help 2 Display
Indicates a malfunction in the secondary
power circuit of the unit. There is a high
open circuit condition. Contact a Factory
Authorized Service Agent if this happens.
Indicates an open in the thermal protection
circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this happens.
The malfunctions that correspond to Help
2, 3, 4, 5, and 9 are thermal related. The
High Temperature LED turns on along with
the blinking Output LED.
Help 9 Display
Indicates a short in the thermal protection
circuitry located on the top heat sink. Con-
tact a factory Authorized Service Agent if
this happens.
Help 3 Display
A malfunction relating to Help 0 will cause
the the Output LED to turn off and stay off,
but the High Temperature LED turns on and
Indicates the bottom heat sink has over-
heated. The unit has shut down to allow the
OM-2233 Page 26
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6-4. Troubleshooting
Trouble
Remedy
No weld output; unit completely
inoperative.
See Section 6-3, Troubleshooting Help Aids.
No weld output; Output LED on.
No weld output; Overtemp LED on.
Erratic or improper weld output.
Fan not operating.
Wandering arc
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Shield weld zone from drafts.
Tungsten electrode oxidizing and not re-
mainingbright after conclusion of weld.
Allow adequate postflow time to shield tungsten while it cools, after welding stops.
Water in torch. Refer to torch manual.
OM-2233 Page 27
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SECTION 8 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_7/2006
Y
Whenever possible and practical, use DC weld output instead of AC weld output.
8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
(For Use With Mild Or Stainless Steel)
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.010” (1 mm)
.020” (1 mm)
.040” (1 mm)
1/16” (1.6 mm)
3/32” (2.4 mm)
1/8” (3.2 mm)
5/32” (4.0 mm)
3/16” (4.8 mm)
1/4” (6.4 mm)
Up to 25
15-40
Up to 20
15-35
25-85
20-80
50-160
50-150
130-250
225-360
300-450
400-500
600-800
135-235
250-400
400-500
500-750
750-1000
♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
8-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC
Welding With Inverter Machines
Y
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor-
mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
2-1/2 Times
Electrode Diameter
1
Grinding Wheel
Radial Grinding
Causes Wandering Arc
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminatedcausing lower weld quality.
3
2
1
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
Flat
3
4
Diameter of this flat determines amperage
capacity.
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc
4
Straight Ground
Grind lengthwise, not radial.
OM-2233 Page 29
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SECTION 9 − GUIDELINES FOR (GTAW) TIG WELDING
gtaw 7/2006
9-1. Positioning The Torch
Y
Grinding the tungsten elec-
trode produces dust and fly-
ing sparks which can cause
injury and start fires. Use lo-
cal exhaust (forced ventila-
tion) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Tho-
rium dust contains low-level
radioactivematerial. Proper-
ly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flam-
mables away.
3
2
4
90°
1
1
Workpiece
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10−15°
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
4
5
6
Tungsten Electrode
10−25°
Select and prepare tungsten
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide ade-
quate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimumof 3/16 in diameter.
5
6
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
1/16 in
3/16 in
Bottom View Of Gas Cup
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
Om-2233 Page 30
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9-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
15°
Welding direction
Form pool
Tilt torch
Add filler metal
Remove rod
Move torch to front
of pool. Repeat process.
ST-162 002-B
9-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
15°
10°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
15°
30°
ST-162 003 / S-0792
OM-2233 Page 31
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SECTION 10 − STICK WELDING (SMAW) GUIDELINES
10-1. Stick Welding Procedure
Y
Y
Weld current starts when
electrode touches work-
piece.
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
1
Workpiece
Make sure workpiece is clean be-
fore welding.
5
2
3
Work Clamp
Electrode
4
2
A small diameter electrode requires
less current than a large one. Fol-
low electrode manufacturer’s
instructions when setting weld am-
4
5
6
Insulated Electrode Holder
Electrode Holder Position
Arc Length
3
Arc length is the distance from the
electrodeto the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
6
1
7
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before mak-
ing another weld pass.
Tools Needed:
stick 12/96 − ST-151 593
OM-2233 Page 32
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10-2. Electrode and Amperage Selection Chart
3/32
1/8
6010
&
6011
5/32
3/16
7/32
1/4
6010
6011
EP
EP
ALL
ALL
ALL
DEEP
DEEP
LOW
MIN. PREP, ROUGH
HIGH SPATTER
1/16
5/64
3/32
6013 EP,EN
GENERAL
1/8
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
6013
7014 EP,EN
ALL
MED
LOW
5/32
3/16
7/32
1/4
3/32
1/8
7018
EP
ALL
FLAT
HORIZ LOW
FILLET
ALL
ALL
SMOOTH, EASY,
FASTER
7024 EP,EN
NI-CL
308L
EP
EP
LOW
LOW
CAST IRON
STAINLESS
5/32
3/16
7014
7/32
1/4
3/32
1/8
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
7018
7024
3/32
1/8
5/32
3/16
3/32
1/8
Ni-Cl
308L
5/32
Ref. S-087 985-A
10-3. Striking an Arc − Scratch Start Technique
1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to work-
piece, use a quick twist to free it.
2
3
S-0049
10-4. Striking an Arc − Tapping Technique
1
1
2
3
Electrode
Workpiece
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
2
3
S-0050
OM-2233 Page 33
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10-5. Positioning Electrode Holder
10°-30°
90°
90°
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10°-30°
45°
45°
End View of Work Angle
Side View of Electrode Angle
S-0060
FILLET WELDS
10-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
10-7. Good Weld Bead Characteristics
1
Fine Spatter
2
3
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
No Overlap
1
3
Good Penetration into Base
Metal
2
4
5
S-0052-B
OM-2233 Page 34
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10-8. Conditions That Affect Weld Bead Shape
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
NOTE
Correct Angle
Angle Too Large
Angle Too Small
10° - 30°
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Long
Too Short
ARC LENGTH
Normal
Fast
Slow
TRAVEL SPEED
S-0061
10-9. Electrode Movement During Welding
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
NOTE
1
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
2
1
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
3
S-0054-A
OM-2233 Page 35
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10-10. Butt Joints
1
Tack Welds
1
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be-
fore final weld.
2
2
Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3
Single V-Groove Weld
Good for materials 3/16 − 3/4 in
(5-19 mm) thick. Cut bevel with oxy-
acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
30°
1/16 in
(1.6 mm)
4
Create 30 degree angle of bevel on
materials in V-groove welding.
3
4
Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).
S-0662
10-11. Lap Joint
30°
1
2
Electrode
30°
Or Less
Or Less
1
Single-LayerFillet Weld
Move electrode in circular motion.
Multi-Layer Fillet Weld
1
3
Weld a second layer when a heavi-
er fillet is needed. Remove slag be-
fore making another weld pass.
Weld both sides of joint for maxi-
mum strength.
3
2
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
S-0063 / S-0064
10-12. Tee Joint
1
2
Electrode
Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
1
45°
Or Less
For maximum strength weld both
sides of upright section.
2
2
3
Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in Section
10-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-2233 Page 36
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10-13. Weld Test
1
2
3
Vise
Weld Joint
Hammer
3
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
2 To 3 in
(51-76 mm)
2
2
1
1/4 in
(6.4 mm)
1
S-0057-B
10-14. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Arc length too long.
Corrective Actions
Reduce arc length.
Use dry electrode.
Damp electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
10-15. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Reduce arc length or voltage.
Arc length too long or voltage too high.
OM-2233 Page 37
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10-16. Troubleshooting − Incomplete Fusion
IncompleteFusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Possible Causes
Insufficient heat input.
Corrective Actions
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
10-17. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow fusion between weld metal and
base metal.
Lack of Penetration
Possible Causes
Good Penetration
Corrective Actions
Improper joint preparation.
Improper weld technique.
Insufficient heat input.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Keep arc on leading edge of weld puddle.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
10-18. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal and
hangingunderneath weld.
Excessive Penetration
Good Penetration
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-2233 Page 38
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10-19. Troubleshooting − Burn-Through
Burn-Through− weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
10-20. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
10-21. Troubleshooting − Distortion
Distortion− contraction of weld met-
al during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-2233 Page 39
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SECTION 11 − PARTS LIST
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13
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26
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25
26
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27
34
11
8
6
19
18
16
401
400
402
14
10
32
3
15
614
2
29
4
9
1
33
5
600
803 107-E
Figure 11-1. Main Assembly
OM-2233 Page 40
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . . . . . . . . . . . . . . . Fig11-2 . . . . Panel, Front W/Cmpnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . Fig11-3 . . . . Panel, Rear W/Cmpnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . Fig11-4 . . . . Magnetics Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . Fig11-5 . . . . Windtunnel, W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . Fig11-7 . . . . Base Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . S1 . . . . . 128756 . . . . Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . PM1 . . . . . 204821 . . . . Kit, Input/Pre-Regulator Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . . . . 049611 . . . . Tubing, Cop .540 Od X .123 Wall X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . 196727 . . . . Cable, Power 10 Ft 12ga 4c Blk/Red/Wht/Grnyel . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . +195643 . . . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . 206108 . . . . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . 195663 . . . . Strap, Shoulder 6 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . . . 189782 . . . . Insulator, Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . C7 . . . . . 213974 . . . . Capacitor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 . . . . . . . . . . . . . . . . 189778 . . . . Plug, W/Leads Vfb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . 202400 . . . . Plug, W/Leads Boost Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . . . . 189779 . . . . Cable, Lem W/Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 . . . . . . . . . . . . . . . . 189784 . . . . Insulator, Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
26 . . . . . . . . . . . . . . . . 198147 . . . . Label, Side Maxstar 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
27 . . . . . . . . . . . . . . . . 199478 . . . . Label, Miller 6.000 X 2.500 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
28 . . . . . . . . . . . . . . . . 203990 . . . . Label, Warning General Precautionary (Non CE Models) . . . . . . . . . . . . 2
28 . . . . . . . . . . . . . . . . . 179310 . . . . Label, Warning General Precautionary (CE Models) . . . . . . . . . . . . . . . . 2
29 . . . . . . . . . . . . . . . . 185835 . . . . Label, Warning Electric Shock/Exploding Parts (Non CE Models) . . . . . . 1
29 . . . . . . . . . . . . . . . . . 185836 . . . . Label, Warning Electric Shock/Exploding Parts (CE Models) . . . . . . . . . 1
30 . . . . . . . . . . . . . . . . . 208998 . . . . Label, Rating Card Code 122 Serial & Stock Number . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . 182826 . . . . Label, Warning Electric Shock Power Cord . . . . . . . . . . . . . . . . . . . . . . . . 1
33 . . . . . . . . . . . . . . . . 207310 . . . . Core, Toroidal (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
34 . . . . . . . . . . . . . . . . 215002 . . . . Clip, Support PC Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
400 . . . . . PC2 . . . . . 200851 . . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC2 . . . . . 230162 . . . . Circuit Card Assy, Power Interconnect (CE ROHS) . . . . . . . . . . . . . . . . . 1
401 . . . . . PC1 . . . . . 206129 . . . . Circuit Card Assy, Inverter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
401 . . . . . PC1 . . . . . 230166 . . . . Circuit Card Assy, Inverter Control (CE ROHS) . . . . . . . . . . . . . . . . . . . . . 1
402 . . . . PC10 . . . . 200841 . . . . Circuit Card Assy, Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
402 . . . . PC10 . . . . 230170 . . . . Circuit Card Assy, Boost Control (CE ROHS) . . . . . . . . . . . . . . . . . . . . . . . 1
403 . . . . . PC9 . . . . . 199506 . . . . Circuit Card Assy, Input Filter (CE Models Only) . . . . . . . . . . . . . . . . . . . . 1
403 . . . . . PC9 . . . . . . 230207 . . . . Circuit Card Assy, Input Filter (CE ROHS) . . . . . . . . . . . . . . . . . . . . . . . . . 1
600 . . . . . . . . . . . . . . . 229333 . . . . Screw, M10−1.5 x 20 Hex Hd−pln 8.8 Pld Sems . . . . . . . . . . . . . . . . . . . . 2
601 . . . . . . . . . . . . . . . 083883 . . . . Washer, Lock .402 id x 0.709 od x.087t Stl Split10mm . . . . . . . . . . . . . . 2
614 . . . . . . . . . . . . . . . 136343 . . . . Screw, K50 x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . 2
615 . . . . . . . . . . . . . . . 229334 . . . . Screw, M 5−.8 x 35 pan hd phl stl pld sems . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts.
Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 41
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6
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7
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4
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2
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15
11
16
8
202 508-E
Figure 11-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . . . . . . . . . . . . . . . 194242 . . . . Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . 195647 . . . . Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . 202325 . . . . Panel, Front Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . 174992 . . . . Knob, Pointer .840 Dia X .250 ID w/Spring Clip−.21 . . . . . . . . . . . . . . . . . 2
5 . . . . . . . . . . . . . . . . . 174991 . . . . Knob, Pointer 1.250 Dia X .250 ID w/Spring Clip−.21 . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . . . . 202323 . . . . Nameplate, Miller Maxstar 200STR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . . . . 202722 . . . . Nameplate, Miller Maxstar 200STR (CE Models Only) . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . 178355 . . . . Nut, 375−32 .54hex .25h Nyl Flange .62d . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 . . . . . . . . . . . . . . . . . 202553 . . . . Rcpt, Tw Lk Insul Fem(Dinse Type)50/70 Series Wsl . . . . . . . . . . . . . . . . 2
9 . . . . . . . . . . . . . . . . . 207253 . . . . Plug, Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . 200659 . . . . Lead List, Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . . 185712 . . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 . . . . . . . . . . . . . . . . . 185713 . . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
13 . . . . . . . . . . . . . . . . . 185714 . . . . Washer, Tooth 20MM ID X 32MM OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 . . . . . . . . . . . . . . . . . 185717 . . . . Nut, M20 X 1.5 1.0625 Hex .19 H Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . . . . . . . . . . . . . . 185718 . . . . O-Ring 0.989 ID X 0.070 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . . . . . 186228 . . . . O-Ring 0.739 ID X 0.070 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 . . . . . . . . . . . . . . . . . 202326 . . . . Recpt w/leads and plug 14-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . . 217272 . . . . Circuit Card Assy, Front Panel Interface W/Program . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . . *213922 . . . . Circuit Card Assy, Front Panel Interface W/Program . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . **231249 . . . . Circuit Card Assy, Front Panel Interface W/Program (CE ROHS) . . . . . . 1
602 . . . . . . . . . . . . . . . 231383 . . . . Washer, Tooth.377 ID X 0.507 OD X .022T STL PLD INT.375 . . . . . . . . . 3
603 . . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
* For models with stock number 907036 or 907037.
** For models with stock number 907355.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 42
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202 397-E
2
Figure 11-3.Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . . . . . . . . . . . . . . . 194242 . . . . Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . 206053 . . . . Panel, Rear Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . 195646 . . . . Panel, Rear Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . 201155 . . . . Bushing, Strain Relief .450/.709 Id X1.068 Mtg Hole . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . 207253 . . . . Plug, Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
600 . . . . . . . . . . . . . . . 198245 . . . . Nut, Conduit .750 Npt Pld 1.388 Od X .150 Thk . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 43
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603
604
613
613
3
17
605
603
13
14
617
10
12
12
9
617
1
14
13
611
604
605
614
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6
202 398-H
Figure 11-4. Magnetics Assembly w/Components
Part
No.
Item
No.
Dia.
Mkgs.
Description
Quantity
1 . . . . . . . . . . . . . . . . . 195649 . . . . Panel, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . FM1 . . . . . 230808 . . . . Fan, Muffin 24vdc 4200 RPM 140 CFM 4.125 MTG HOLES . . . . . . . . 1
6 . . . . . . . CR1 . . . . . 198549 . . . . Relay, Encl 24vdc Spst 35a/300vac 4pin Flange Mtg . . . . . . . . . . . . . . . . 1
8 . . . . . . . . . . . . . . . . . 189790 . . . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . L2 . . . . . 210599 . . . . Coil, Inductor 9t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . L3 . . . . . 206020 . . . . Coil, Inductor 14t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . T1 . . . . . 212268 . . . . Xfmr, HF Litz/Litz w/Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . 109056 . . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . . . . . 2
13 . . . . . . . . . . . . . . . . 196512 . . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 . . . . . . . . . . . . . . . . 196514 . . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-2233 Page 44
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
17 . . . . . . . . . . . . . . . . 213208 . . . . Connector, Faston Male 1/4 Ring W/75deg Bend . . . . . . . . . . . . . . . . . . . 1
603 . . . . . . . . . . . . . . . 057357 . . . . Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . 2
604 . . . . . . . . . . . . . . . 182737 . . . . Screw, 010−32x2.00 Rnd Hd−slt Brs Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 4
605 . . . . . . . . . . . . . . . 229323 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . . 4
611 . . . . . . . . . . . . . . . 136343 . . . . Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . 2
613 . . . . . . . . . . . . . . . 083147 . . . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . 2
614 . . . . . . . . . . . . . . . 010381 . . . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
617 . . . . . . . . . . . . . . . 170647 . . . . Bushing, Snap−in nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 45
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not available unless listed.
4
2
602
6
3
5
7
199 494-F
10
Figure 11-5. Windtunnel w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . . . . . . . . . . . . . . . . 195645 . . . . Panel, Midplain Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . 198634 . . . . Bracket, Front Heatsink Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 198633 . . . . Wind Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . 232856 . . . . Rail, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 . . . . . . . . . . . . . . . . . . 198652 . . . . Bracket, Windtunnel Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 . . . . . . . . . . . . . . . . . +209949 . . . . Heat Sink, Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . . 199497 . . . . Heat Sink, Secondary Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . L1 . . . . . . 189787 . . . . Choke, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . C9 . . . . . . 151328 . . . . Capacitor, Polyp Met Film .0047Uf 1000 Vdc W/T (CE Models Only) . . 1
. . . . . . . . . . . . . . . . . . . . 083147 . . . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High (CE Models Only) 4
602 . . . . . . . . . . . . . . . . 154408 . . . . Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 46
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606
.
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a
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not available unless listed.
2
604
604
5
6
600
601
7
3
602
4
1
199 497-H
Figure 11-6. Heat Sink, Secondary Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . . . . . . . . . . . . . . . . 210783 . . . . Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . D1 . . . . . . 204820 . . . . Kit, Diode, Ultra Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . HD1 . . . . . . 198028 . . . . Transducer, Current 100a Module Supply V+/− 15v . . . . . . . . . . . . . . . . . 1
4 . . . . . . . RT1 . . . . . . 211124 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 18 in Lead . . . . . . . . . . . . . . . . . . 1
5 . . . . . . R2, C6 . . . . 206021 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . R1, C5 . . . . 199138 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . SR1 . . . . . . 199952 . . . . Diode, Power Module 50 Amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
600 . . . . . . . . . . . . . . . . 207451 . . . . Screw, 008−32 x .50 Pan Hd−Phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
601 . . . . . . . . . . . . . . . . 231214 . . . . Screw, 008−32 x 1.00 Pan Hd−phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 1
602 . . . . . . . . . . . . . . . . 207451 . . . . Screw, 008−32 x .50 Pan Hd Phl Stl Pld Sems . . . . . . . . . . . . . . . . . . . . . 1
604 . . . . . . . . . . . . . . . . 207450 . . . . Screw, 004−40 x .37 Pan Hd−torx Stl Pld Cone Sems . . . . . . . . . . . . . . . 4
606 . . . . . . . . . . . . . . . . 229331 . . . . Screw, M 6−1.0 x 16 Pan Hd−phl Stl Pld Sems . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 47
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H
a
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a
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not available unless listed.
199 493-B
Figure 11-7. Base Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1 . . . . . . . . . . . . . . . . . . 195644 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . 019663 . . . . Mount, Nprn 15/16odx3/8rec 3/16x3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2233 Page 48
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
*
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
*
*
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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