OM-842
162074B
August 1997
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Programmable Precision Controller For
Welding Power Source
Intellitig MPC
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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. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
5
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
8
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Connecting Remote Pendant Or Equivalent User-Wired Control . . . . . . . . . . . . . . . . . . . . . .
2-2. Remote 4 Socket Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. User Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Setting DIP Switch SW1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
10
11
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Ammeter And Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Mode Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Program/Run/Reset Keyed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Parameter Select Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Right/Increase Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Left/Decrease Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Purge Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Remote Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
13
13
13
14
14
14
14
15
15
15
SECTION 4 – INTRODUCTION TO PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Modes Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
16
17
SECTION 5 – PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Semi-Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Manual GTAW Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. SMAW Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Editing A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Dry Run Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Stop Watch Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Linking Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Combining Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
25
29
31
31
32
32
32
33
SECTION 6 – SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-1. Gas Tungsten Arc Welding (GTAW) In The Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Gas Tungsten Arc Welding (GTAW) In The Semi-Automatic Modes . . . . . . . . . . . . . . . . . . .
6-3. Gas Tungsten Arc Welding (GTAW) In The Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Shielded Metal Arc Welding (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Executing Linked Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Executing Combined Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
36
37
37
37
38
38
SECTION 7 – DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Diagnostics Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
39
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
WARRANTY
Stick = SMAW
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
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.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D
D
D
If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D
D
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
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
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
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.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
FUMES AND GASES can be hazardous.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
D
D
Use AC output ONLY if required for the welding process.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If AC output is required, use remote output control if present on
unit.
D
D
If ventilation is poor, use an approved air-supplied respirator.
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).
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D
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.
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.
D
D
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.
D
D
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.
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 if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
D
D
D
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.
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
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.
Always ventilate confined spaces or use
approved air-supplied respirator.
D
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
D
D
Do not touch hot parts bare handed.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow cooling period before working on gun or
torch.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
NOISE can damage hearing.
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
damagehearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is
high.
D
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
D
Watch for fire, and keep a fire extinguisher nearby.
CYLINDERS can explode if damaged.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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.
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).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D
D
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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
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.
FLYING METAL can injure eyes.
D
D
Turn face away from valve outlet when opening cylinder valve.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
D
Wear approved safety glasses with side
shields even under your welding helmet.
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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.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
Do not install unit near flammables.
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.
H.F. RADIATION can cause interference.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Use equipment of adequate capacity to lift and
support unit.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
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.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
D
D
Have the installation regularly checked and maintained.
Reduce current or reduce duty cycle before
starting to weld again.
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
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
D
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
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.
Be sure this welding machine is installed and grounded
according to this manual.
D
D
Do not press gun trigger until instructed to do
so.
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.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-842 Page 3
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1-5. 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:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-842 Page 4
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 5/97
1-1. Signification des symboles
SignifieMise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
Y
Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
1-2. Dangers relatifs au soudage à l’arc
Y
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne doi-
vent être confiés qu’à des personnes qualifiées.
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.
Au cours de l’utilisation, tenir toute personne à l’écart et plus par-
ticulièrement les enfants.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimenta-
tion électrique.
D
Arrêter les convertisseurs, débrancher le courant électrique, et dé-
charger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
D
D
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
LES FUMÉES ET LES GAZ peuvent
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact phy-
sique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
être dangereux.
Le soudage génère des fumées et des gaz. Leur
D
D
D
D
inhalation peut être dangereux pour votre santé.
D
Eloigner votre tête des fumées. Ne pas respirer
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
les fumées.
D
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimenta-
tion d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consomma-
bles, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxy-
gène provoquant des blessures ou des accidents mortels. S’assu-
rer que l’air de respiration ne présente aucun danger.
Si l’utilisation d’une source électrique àcourant électrique s’avère néces-
saire, se servir de la fonction de télécommande si l’appareil en est équipé.
D
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-
lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assu-
rer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D
D
D
D
D
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
D
D
D
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de
retour.
OM-842 Page 5
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LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
LES ACCUMULATIONS DE GAZ ris-
quent 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 provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
D
Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIÈCES CHAUDES peuvent pro-
voquer des brûlures graves.
D
D
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas re-
garder l’arc.
Porter des vêtements de protection constitué dans une matière dura-
ble, résistant au feu (cuir ou laine) et une protection des pieds.
D
D
Ne pas toucher des parties chaudes à mains nues
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincel-
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
les, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de
LE BRUIT peut affecter l’ouïe.
métal chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneuse-
ment avec des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facile-
ment passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
D
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
Si des BOUTEILLES sont endomma-
gées, elles pourront exploser.
mité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
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
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 sur la pièce le plus près possible de la zone de sou-
dage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’élec-
trocution et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
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 dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans re-
vers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
manipuler avec précaution.
D
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étin-
celles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnai-
re ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
cuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une
D
D
D
D
D
bouteille.
D
D
D
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-
lisation ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz com-
primé, les équipements associés et les publications P-1 CGA énu-
mérées dans les normes de sécurité.
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 vo-
lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-842 Page 6
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou à proxi-
mité de surfaces infllammables.
D
D
Rester à l’écart des organes mobiles comme le
ventilateur.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D
D
Ne pas installer l’appareil à proximité de produits inflammables
Ne pas surcharger l’installation électrique – s”assurer que l’alimen-
tation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de ra-
dio–navigationet de communication, les services
de sécurité et les ordinateurs.
D
D
Utiliser l’anneau de levage uniquement pour sou-
lever l’appareil, NON PAS les chariot, les bouteil-
les de gaz ou tout autre accessoire.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appa-
reil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interfé-
rences éventuelles.
D
D
Prévoir une période de refroidissement, respec-
ter le cycle opératoire nominal.
Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
D
Ne pas obstruer les passages d’air du poste.
provoquer des interférences.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir-
cuits imprimés.
D
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit com-
D
D
Établir la connexion avec la barrette de terre
patible électromagnétiquement.
avant de manipuler des cartes ou des pièces.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires tel-
les que le déplacement du poste, l’utilisation de câbles blindés, l’uti-
lisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
D
D
D
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
LES FILS DE SOUDAGE peuvent pro-
voquer des blessures.
D
D
Porteurs de stimulateur cardiaque, restez à dis-
D
D
Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
tance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’appro-
cher des opérations de soudage à l’arc, de gou-
geage ou de soudage par points.
Ne pas diriger le pistolet vers soi, d’autres person-
nes ou toute pièce mécanique en engageant le fil
de soudage.
OM-842 Page 7
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1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
RecommendedSafe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
NationalElectrical Code, NFPA Standard 70, de la National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir ex-
aminé plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Re-
search Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiqueset champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les con-
clusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
2
3
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4
5
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
OM-842 Page 8
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SECTION 2 – INSTALLATION
2-1. Connecting Remote Pendant Or Equivalent User-Wired Control
A user-wired equivalent to the remote pendant may be connected to the control
NOTE
unit. However, connections must be made for a Stop push button even if it is not
used in unit operation. Since the Stop button is wired in a normally closed
configuration, if Stop connections are not made, the control unit interprets that as
the Stop button being continually pressed. Refer to Figure 8-1 for a circuit diagram
of the remote pendant.
1
2
Remote Pendant
Remote 4 Receptacle RC3
(See Section 2-2)
3
2
1
3
4
5
Keyway
Plug
Threaded Collar
A
D
C
Use receptacle to connect supplied
remote pendant. User-wired con-
trols equivalent to remote control
are also connected to this
receptacle.
B
To connect to receptacle, align key-
way, insert plug, and tighten
threaded collar.
5
4
sb7.1* 5/94 – Ref. ST-162 479-A / Ref. ST-146 839 / Ref. S-0446-A
2-2. Remote 4 Socket Information
Socket
Socket Information
A
B
C
D
Normally closed contact with socket C, opens when pendant Stop button is pressed.
Normally open contact with socket C, closes when pendant Decrease button is pressed.
Circuit common.
Normally open contact with socket C, closes when pendant Start/Increase button is pressed.
OM-842 Page 9
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2-3. User Relay Contacts
The internal control relay
contacts accessible through
terminal strips 3T and 4T are
rated at 20 amperes, 250 volts.
1
2
3
4
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
AA BB CC
WELD
TIME
CONTACTS
INITIAL TIME INITIAL SLOPE WELD PEAK
FINAL SLOPE
FINAL TIME
POST FLOW
PULSE SIGNAL WIRE FEED
S-157 815
Tools Needed:
Or
Ref. ST-162 477-A / ST-162 841 / Ref. SC-159 862
1
Access Door
pulse signal, and for a wire feeder.
The pulse signal contacts change state as
pulsed output goes between peak and back-
ground amperage.
Each set of weld sequence contacts
changes state at the beginning of the match-
ing part of the weld sequence, and resets at
the end of postflow. For example, the initial
slope contacts change state when initial
slope begins, and reset at the end of post-
flow. The user relay contacts change state
regardless of the time value programmed for
the matching portion of the weld sequence.
Access door is hinged at top, and held
closed with industrial interlock strips. To
open, grasp bottom and pull out firmly.
The wire feed contacts operation is program-
mable, and is explained where needed in
Section 5.
2
3
4
Terminal Strip 3T
Terminal Strip 4T
Connection Label
To make connections, route leads through
openings in either side of access door, and
make connections to terminals according to
the connection label.
Use 3T and 4T to connect external equip- If 0.0 seconds was entered as a time value
ment to internal relay contacts. Pairs of nor- for final slope, the user relay contacts match-
mally closed and normally open contacts are ing final slope and final current would change
provided for each weld sequence step, the
states at the same time.
Close access door.
OM-842 Page 10
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2-4. Setting DIP Switch SW1
Set DIP switch SW1 rocker switch
positions as follows:
1
2
Control Box Front Panel
Retaining Screw Location
Loosen retaining screw, and open
hinged front panel.
3
4
5
Microprocessor Board PC5
DIP Switch SW1
4
2
Positions 7 And 8
Set 7 and 8 according to table to se-
lect Semi-Automatic Modes 1 thru
5.
1
6
Position 4
Set Off to run diagnostics program.
Set On to stop diagnostics pro-
gram, and for all other operations.
7
Position 3
3
Use position 3 to select whether
pulses are defined as frequency or
time values.
Set Off to define as frequency.
Set On to define as time.
8
Positions 1 And 2
Actual numbers 1 thru 8 below rocker
switches are upside down. Positions
5 and 6 are not used.
In Automatic and Semi-Automatic 1
modes, weld amperage can be ad-
justed up or down during weld using
remote pendant. Define amperage
adjustment range limits by setting
positions 1 and 2 according to table.
7
8
6
5
Rocker Switch Settings:
= On
4
Close front panel and tighten retain-
ing screw after setting SW1.
8
7
6
5
4
3
2
1
= Off
Defined
Defined
Position
7
Position
Semi-Automatic
Mode
Amperage
8
Position Position Adjustment
1
2
Limit
On
On
Off
On
Off
On
*1
2
±5 Amperes
On
On
Off
Off
On
Off
On
Off
±10 Amperes
±20 Amperes
±40 Amperes
3
Off
On
Off
On
4
*5
*Semi-Automatic 1 mode is defined when remote Stop
switch is connected. Semi-Automatic 5 mode is defined
when remote Stop switch is not connected.
Tools Needed:
Ref. ST-800 194 / Ref. ST-162 477-A
OM-842 Page 11
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SECTION 3 – OPERATION
3-1. Controls
1
2
3
4
5
6
7
8
9
Voltmeter
Ammeter
Digital Display
3
4
5
6
7
8
10
Left/Decrease Button
Right/Increase Button
Parameter Select Button
Purge Button
9
2
1
Mode Switch
Program/Run/Reset Keyed
Switch
10 Remote Pendant
Ref. ST-162 479-A / Ref. ST-146 839
3-2. Safety Equipment
Wear the following while welding:
1
2
3
1
2
Dry, Insulating Gloves
Safety Glasses With Side
Shields
3
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
3-3. Work Clamp
1
Work Clamp
1
Connect work clamp to a clean,
paint-freelocation on workpiece, as
close to weld area as possible.
Tools Needed:
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93
OM-842 Page 12
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3-4. Ammeter And Voltmeter
1
Ammeter
Meter displays weld amperage out-
put of unit when welding.
1
2
2
Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not nec-
essarily the welding arc due to
cable resistance, poor connec-
tions, etc.
Ref. SC-159 862
3-5. Digital Display
1
Digital Display
Use display to enter and read val-
ues. If weld sequence steps are
shown, the programmed time val-
ues decrease as process time runs
out.
1
3-6. Mode Selector Switch
1
Mode Selector Switch
Use switch to select mode of
operation.
1
OM-842 Page 13
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3-7. Program/Run/Reset Keyed Switch
1
Program/Run/ResetKeyed
Switch
Program
Use to enter, change, and/or ex-
ecute a program.
1
Run
Use to execute a program only. Key
can be removed to prevent unau-
thorized access to program.
Reset
Use before switching between Run/
Program positions when unit is On.
For example, use Program position
to enter program, move to Reset
momentarily, and move to Run to
execute program. Remove key if
desired. If changing program, move
to Reset momentarily before mov-
ing back to Program.
3-8. Parameter Select Push Button
1
Parameter Select Push Button
1
Press switch to select and deselect
parameters in a display (see Sec-
tion 5-1B).
In a display with an either/or option,
press switch to make selection.
3-9. Right/Increase Push Button
1
Right/IncreasePush Button
1
Press switch while a parameter is
selected to increase that parameter
value. Press and hold switch to rap-
idly increase the value.
To zero a parameter value, select pa-
rameter and press Right/Increase
and Left/Decrease switches at the
same time.
Press switch without a parameter
selected to scroll to next display in
the sequence.
3-10. Left/Decrease Push Button
1
Left/Decrease Push Button
Press switch while a parameter is
selected to decrease that parame-
ter value. Press and hold switch to
rapidly decrease the value.
1
To zero a parameter value, select pa-
rameter and press Right/Increase
and Left/Decrease switches at the
same time.
Press switch without a parameter
being selected to scroll to previous
display in the sequence.
OM-842 Page 14
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3-11. Purge Push Button
1
Purge Push Button
Press switch to momentarily ener-
gize gas valve and purge air from
torch shielding gas line, and to allow
shielding gas regulator to be ad-
justed without energizing the weld-
ing circuit.
1
Switch is only active when the re-
peating displays are shown.
3-12. Remote Pendant
1
Remote Pendant
Use for remote operation in the Au-
tomatic and Semi-Automatic
1
modes only. Connect to Remote 4
receptacle.
2
3
2
3
4
Stop Push Button
Start/Increase Push Button
Decrease Push Button
See programming and operating in-
structions for Automatic and Semi-
Automatic modes for push button
functions.
4
Ref. ST-146 839
3-13. Shielding Gas
1
2
3
4
ShieldingGas Cylinder
Valve
Torch Switch
Foot Control
2
1
Open valve on cylinder just before
welding.
3
4
Torch trigger or foot control turns
weld output and gas flow on and off.
Close valve on cylinder when fin-
ished welding.
OR
sb5.2* 2/92 – S-0621-C / ST-159 059
OM-842 Page 15
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SECTION 4 – INTRODUCTION TO PROGRAMMING
4-1. General
Programs are created when parameters are defined in a series of displays. Up to four programs can be entered into each of the four
modes of operation, for a total of sixteen programs. In addition, programs in certain modes can be linked or combined to run in a
user-defined sequence.
This welding power source provides high frequency or scratch starting, preflow timing, start current level control and timing, initial
current level control and timing, initial slope timing, final slope timing, final current level control and timing, postflow timing, and am-
perage control of weld/peak current for either a pulsing or nonpulsing weld current. Pulsing controls include on/off selection, pulse
peak level control and timing, background current level control and timing, and pulse frequency and average current calculations.
4-2. Weld Sequence
In most cases, the weld sequence
Weld/Peak
Current
shown here is used in programming
the control. Which steps are pro-
grammable and what initiates each
step varies from mode to mode.
Initial
Slope
Final
Slope
Initial
Current
Final
Current
Preflow
Postflow
Preflow: The period during which shielding gas flows before an arc is
established.
Start Level (Not Shown): A current level that can be programmed to ease
arc starting.
Initial Current: The beginning maintained current level.
Initial Slope: The ramping of the initial current up to the programmed weld/
peak current level.
Weld/Peak Current: The programmed weld current level (divided into peak
and background current levels when pulsing is enabled).
Final Slope: The ramping down of weld/peak current to the programmed final
current level.
Final Current: The end current level just before the arc is extinguished.
Postflow: The period during which shielding gas flows after the arc has been
extinguished.
Ref. SB-139 983
4-3. Balance Control
When ac output is selected on the
Process Selector switch, a balance
control value must be programmed.
The balance control value can be
used to change the weld arc charac-
teristics for either more penetration
or more cleaning. The electrode
negative (EN) value is user-
programmed,and the electrode pos-
itive (EP) value changes accordingly
so the sum always equals 100%.
Balance Control Waveform Examples
55% Electrode
Positive
More Cleaning
45% Electrode
Negative
32% Electrode
Positive
More Penetration
Balanced
68% Electrode
Negative
50% Electrode
Positive
50% Electrode
Negative
OM-842 Page 16
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4-4. Modes Of Operation
The microprocessor control has four modes of operation: Automatic, Semi-Automatic, Manual GTAW, and SMAW. In abbreviated
form, the modes function as follows:
A. Automatic Mode Sequence
In this mode, the program controls
each step of the weld sequence.
Pressing the Start/Increase push
button starts the sequence, with no
more input required from the opera-
tor.
Weld/Peak
Initial
Slope
Final
Slope
Current
Initial
Current
Final
Current
Preflow
Postflow
The operator can increase or de-
crease weld amperage during weld/
peak current within the defined am-
perage adjustment limits (see Sec-
tion 2-4). This change does not af-
fect the programmed values.
A
A: Momentary closure of Start/Increase push button starts sequence.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
Pressing the Stop push button dur-
ing the weld sequence stops pro-
gram execution and starts postflow.
Initial Current: Time & level programmed.
Initial Slope: Time programmed/Slope calculated by microprocessor
control.
Weld/Peak Current: Time & level programmed.
Final Slope: Time programmed/Slope calculated by microprocessor
control.
Final Current: Time & level programmed.
Postflow: Time programmed/Volume set by gas meter.
Weld/peak current can be increased or decreased during welding.
Stop push button functions throughout sequence.
Ref. SB-139 983
B. Semi-Automatic Mode Sequence
A program created in the Semi-Automatic mode controls certain portions of the weld sequence but requires the operator to control
other portions. The Semi-Automatic mode has five variations. Which portions of the sequence the operator controls, and how the
portions are controlled depends on which variation is used.
In this mode, the end time for weld/
Weld/Peak
Current
peak current is not defined. Pressing
the Start/Increase push button starts
the sequence. The program pro-
ceeds through each step into weld/
peak current. The operator must sig-
nal the end of weld/peak by pressing
the Stop push button, at which time
final slope starts.
Initial
Slope
Final
B
Slope
Initial
Current
Final
Current
Preflow
Postflow
A
The operator can increase or de-
crease weld amperage during weld/
peak current within the defined am-
perage adjustment limits (see Sec-
tion 2-4). This change does not af-
fect the programmed values.
A: Momentary closure of Start/Increase push button starts sequence.
B: Momentary closure of Stop push button ends weld/peak current.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
Initial Current: Time & level programmed.
Pressing the Stop push button be-
fore the start of weld/peak current
stops program execution and starts
postflow. Pressing the Stop push
buttonafter the end of weld/peak has
been signalled has no effect.
Initial Slope: Time programmed/Slope calculated by microprocessor
control.
Weld/Peak Current: Time undefined/Level programmed.
Final Slope: Time programmed/Slope calculated by microprocessor
control.
Final Current: Time & level programmed.
Postflow: Time programmed/Volume set by gas meter.
Weld/peak current can be increased or decreased during welding.
Stop push button functions up to the signaled end of weld/peak current.
Ref. SB-139 983
Figure 4-1. Semi-Automatic 1 Mode Sequence
OM-842 Page 17
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In this mode, time values are not de-
fined for initial current, weld/peak
current, and final current. The micro-
processor control operates in a mo-
mentary-contact, single button for-
mat. The operator presses the Start/
Increase push button to start the pro-
gram, presses it again to signal the
end of initial current, presses it again
to signal the end of weld/peak cur-
rent, and presses it for a last time to
signal the end of final current.
Weld/Peak
Current
Initial
Slope
Final
C
Slope
Initial
Final
Current
Current
B
D
Preflow
Postflow
A
A: Momentaryclosure of Start/Increase push button starts sequence.
B: Momentaryclosure of Start/Increase push button ends initial current.
C: Momentaryclosure of Start/Increase push button ends weld/peak cur-
The weld amperage cannot be in-
creased or decreased once the se-
quence has started.
rent.
D: Momentaryclosure of Start/Increase push button ends final current.
If Stop Button Detect is enabled in
the weld program, pressing the Stop
push button stops program execu-
tion and starts postflow. If Stop But-
ton Detect is disabled, pressing the
Stop push button has no affect.
Postflow starts if the arc is manually
broken.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
Initial Current: Time undefined/Level programmed.
Initial Slope: Time programmed/Slope calculated by microprocessor
control.
Weld/Peak Current: Time undefined/Level programmed.
Final Slope: Time programmed/Slope calculated by microprocessor
control.
Final Current: Time undefined/Level programmed.
Postflow: Time programmed/Volume set by gas meter.
Weld/peak current cannot be increased or decreased during welding.
Stop push button functions throughout sequence if Stop Button Detect is en-
abled in the program.
Ref. SB-139 983
Figure 4-2. Semi-Automatic 2 Mode Sequence
In this mode, time values are not de-
fined for initial current, weld/peak
current, and final current. The micro-
processor control operates in a
maintained-contact, single button
format. The operator presses and
holds the Start/Increase push button
to start the sequence. The Start/In-
crease push button is released to
signal the end of initial current. The
sequence will then cycle through to
weld/peak current. The operator
presses and holds the Start/In-
crease push button to signal the end
of weld/peak current. The sequence
will then cycle through to final cur-
rent. The Start/Increase push button
is released to signal the end of final
current.
Weld/Peak
Initial
Slope
Final
Current
C
Slope
Initial
Current
Final
Current
B
D
Preflow
Postflow
A
A: Maintainedclosure of Start/Increase push button starts sequence.
B: Release of Start/Increase push button ends initial current.
C: Maintainedclosure of Start/Increase push button ends weld/peak cur-
rent.
D: Release of Start/Increase push button ends final current.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
The weld amperage cannot be in-
creased or decreased once the se-
quence has started.
Initial Current: Time undefined/Level programmed.
Initial Slope: Time programmed/Slope calculated by microprocessor
control.
If Stop Button Detect is enabled in
the weld program, pressing the Stop
push button stops program execu-
tion and starts postflow. If Stop But-
ton Detect is disabled, pressing the
Stop push button has no affect.
Postflow starts if the arc is manually
broken.
Weld/Peak Current: Time undefined/Level programmed.
Final Slope: Time programmed/Slope calculated by microprocessor
control.
Final Current: Time undefined/Level programmed.
Postflow: Time programmed/Volume set by gas meter.
Weld/peak current cannot be increased or decreased during welding.
Stop push button functions throughout sequence if Stop Button Detect is en-
abled in the program.
Ref. SB-139 983
Figure 4-3. Semi-Automatic 3 Mode Sequence
OM-842 Page 18
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In this mode, time values are not de-
fined for initial current, initial slope,
weld/peak current, and final slope.
The operator uses the Start/In-
crease and Decrease push buttons
to vary the weld current level once
initial current starts.
Weld/Peak
Current
The first momentary closure of the
Start/Increasepush button starts the
sequence. Following start level,
each time the Start/Increase push
button is pressed and held weld out-
put increases at a rate calculated by
the microprocessor control. The rate
of increase depends on the pro-
grammed initial current level, weld/
peak current level, and initial slope
time. Each time the Decrease push
button is pressed and held, weld out-
put decreases at a rate calculated by
the microprocessor control. The rate
of decrease depends on the pro-
grammedweld/peak current level, fi-
nal current level, and final slope
time. The weld output will maintain at
the level that exists when either the
Start/Increase or Decrease push
button is released. The programmed
values that normally define the weld/
peak current level define the upper
limit that the Start/Increase push but-
ton can command.
Initial
Slope
Final
C
D
Slope
Initial
Current
Final
Current
B
Preflow
Postflow
A
A: Momentaryclosure of Start/Increase push button starts sequence.
B: Maintained closure of Start/Increase push button increases weld out-
put; maintained closure of Decrease push button decreases weld
output.
C: Release of Start/Increase or Decrease push button sets weld/peak
current (output remains at level existing when push button released).
D: Maintainedclosure of Decrease push button decreases weld output to
programmedfinal current level; final current starts.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
Initial Current: Time undefined/Level programmed.
Initial Slope: Controlled by Start/Increase and Decrease push buttons/
Slope rate of change calculated by microprocessor control.
The weld output level can be in-
creased and decreased indefinitely
until the operator decreases the
weld current down to the pro-
grammed final current level. At this
point the sequence enters final cur-
rent and then postflow. If the weld
current never exceeds the pro-
grammedfinal current value, the op-
erator must decrease the weld cur-
rent to zero, at which time postflow
will begin.
Weld/PeakCurrent: Time undefined/Level determined by weld output level
when Start/Increase or Decrease push button released.
Final Slope: Controlled by Start/Increase and Decrease push buttons/
Slope rate of change calculated by microprocessor control.
Final Current: Time & Level programmed.
Postflow: Time programmed/Volume set by gas meter.
Weld/peak current can be increased or decreased during welding.
Stop push button functions throughout sequence if Stop Button Detect is en-
abled in the program.
If Stop Button Detect is enabled in
the weld program, pressing the Stop
push button stops program execu-
tion and starts postflow. If Stop But-
ton Detect is disabled, pressing the
Stop push button has no affect.
Postflow starts if the arc is manually
broken.
Ref. SB-139 983
Figure 4-4. Semi-Automatic 4 Mode Sequence
OM-842 Page 19
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In this mode, a single momentary
closure of the Start/Increase push
button starts the sequence. The pro-
gram continues through the pro-
grammed sequence of events until
weld/peak current. The operator
presses the Start/Increase push but-
ton to signal the end of weld/peak
current, at which time final slope
starts.
Weld/Peak
Current
Initial
Slope
Final
B
Slope
Initial
Current
Final
Current
Preflow
Postflow
A
A: Momentaryclosure of Start/Increase push button starts sequence.
B: Momentaryclosure of Start/Increase push button ends weld/peak cur-
The weld amperage cannot be in-
creased or decreased once the se-
quence has started, and the Stop
push button is not functional. Post-
flow starts if the arc is manually
broken.
rent.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
Initial Current: Time & level programmed.
Initial Slope: Time programmed/Slope calculated by microprocessor
control.
Weld/Peak Current: Time undefined/Level programmed.
Final Slope: Time programmed/Slope calculated by microprocessor
control.
Final Current: Time & level programmed.
Postflow: Time programmed/Volume set by gas meter.
Weld/peak current cannot be increased or decreased during welding.
Stop push button is not functional throughout sequence.
Ref. SB-139 983
Figure 4-5. Semi-Automatic 5 Mode Sequence
C. Manual GTAW Mode Sequence
A Manual GTAW program requires
the operator to perform most of the
control of the welding process. This
is carried out through the use of a re-
mote control providing contactor and
amperage control (not the Remote
Pendant). High frequency is avail-
able for non-contact weld starts.
Weld/Peak
Current
Initial
Slope
Final
Slope
Initial
Final
Current
Current
B
Preflow
A
Postflow
C
Preflow starts when the remote con-
tactor control is closed. Following
arc ignition, the weld sequence en-
ters initial current. Once initial cur-
rent starts, the operator controls the
output level through the use of the
remote amperage control. The maxi-
mum output that can be commanded
is defined when the program is
created. The minimum value that
can be commanded is the defined
initial current level. Postflow starts
when the remote contactor control is
opened.
A: Closure of remote contactor control starts sequence.
B: Arc ignition starts initial current.
C: Opening of remote contactor control starts postflow.
Preflow: Time programmed/Volume set by gas meter.
Start Level (Not Shown): Time & level programmed.
Initial Current: Time undefined/Level programmed.
Initial Slope:
Not separate steps.
Current level controlled by remote
amperage control.
Weld/Peak Current:
Final Slope:
Final Current:
Postflow: Time programmed/Volume set by gas meter.
Remote Pendant not used.
Weld/peak current can be increased or decreased during welding.
Ref. SB-139 983
D. SMAW Mode
A program entered in the SMAW mode does not follow the weld sequence shown in Section 4-2. On/Off control of the welding power
source contactor is accomplished through a remote contactor control, and arc initiation and extinguishing are done manually. Weld
output can be controlled remotely or kept at a defined level, depending on programmed parameters. If remote control is used, the
maximum output that can be commanded is defined when the program is created. The minimum is the minimum output the welding
power source is capable of.
OM-842 Page 20
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SECTION 5 – PROGRAMMING
5-1. General
T H E
I S
A D J U S T M E N T
O R X X
L I M I T
A M P S
+
–
A. Displays
The displays presented by the microprocessor control either
provide information to the user, or allow the user to enter infor-
mation needed for program execution. The displays vary from
mode to mode. Within each mode, the displays are always
shown in the same sequence.
E. Initial Displays
Each time power is applied to the microprocessor control or a
reset is initiated on the Program/Run/Reset keyed switch (see
Section 3-7), four displays are shown in sequence, each dis-
play shown once.
Pressing the Right/Increase push button allows the user to
move forward through the sequence of displays, beginning to
end. Pressing the Left/Decrease push button allows the user
to move backward through the displays. Either push button
can be used to access displays.
1.
2.
3.
The first initial display identifies the welding power
source and microprocessor control. The display
shows:
B. Selecting And Defining A Parameter
* S Y N C R O W A V E
M P C M O D U L E
3 5 1 *
The user defines a parameter by entering a value for it. This is
normally a three-step process (exceptions are noted in the
text), that is carried out as follows:
1.
2.
3.
Press Parameter Select (see Section 3-8) to select the
parameter (the parameter flashes).
The next display scrolls into view.
The second initial display indicates the part number of
the software program contained in the unit, and the re-
vision level of the program. The display shows:
Press Right/Increase (see Section 3-9) or Left/De-
crease (see Section 3-10) to enter the desired value.
Press Parameter Select again to deselect the parame-
ter (the parameter stops flashing). If the display
contains more than one parameter, the next parameter
will be selected.
P A R T
#
X X X X X X
L E V E L
R E V I S I O N
X
Parameters are always selected in sequence. If the existing
value for the first parameter is acceptable, but another param-
eter needs to be changed, use the Parameter Select push
button to select and deselect the first parameter without
changing its value. The next display in a mode cannot be ac-
cessed if a parameter remains selected (flashing) in the
existing display.
The next display scrolls into view.
The third initial display indicates the copyright for the
program in the unit. The display shows:
C O P Y R I G H T
1 9 9 3
C. Defining Program Number
M I L L E R E L E C T R I C
M F G .
In some displays, the first parameter is the program number.
This number provides a means of identifying programs en-
tered into the selected mode. Since parameters are selected in
sequence, even when the program number is not being
changed it must be selected and deselected before the next
parameter can be changed.
The next display scrolls into view.
4.
The fourth initial display indicates the amperage ad-
justment limits that have been defined (see Section
2-4). The value cannot be modified through this dis-
play. The display shows:
The program number is normally defined in the first display
used to enter information. The defined number carries over to
the following displays and does not need to be redefined as
long as the original defined number applies.
T H E
I S
A D J U S T M E N T
O R X X
L I M I T
A M P S
+
–
To avoid unnecessary repetition, this manual does not indicate
that the program number can be redefined in each display con-
taining it. It is assumed that when a program is entered, each
display in sequence applies to the same program.
The repeating displays scroll into view.
F. Repeating Displays (Ready Condition)
D. Display Representation
After the initial displays are shown, repeating displays are
shown. These displays scroll continuously until the operator
takes action. The presence of the repeating displays indicates
that the microprocessor control is ready for a program to be en-
tered, or for a program to be executed.
When the microprocessor control’s digital display is repre-
sented in this Owner’s Manual, an “X” is used to represent a
parameter whose contents may vary, as shown in the following
example:
OM-842 Page 21
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5-2. Automatic Mode
The program number in a display can
be increased by pressing Parameter
Select while any of the repeating
displays are shown. This allows
other programs to be accessed.
NOTE
If needed, see Section 5-1B for
NOTE
NOTE
information on selecting and defining
a parameter.
1.
The first repeating display indicates the program num-
ber and that the microprocessor control is ready for
program execution. The display shows:
Weld output options, such as the use
of pulsing, high frequency, and ac or
dc output, affect how a program is
entered in the Automatic mode. Be
sure to follow all applicable steps,
and only the applicable steps, as
determined by the selected options.
P R O G R A M
R E M O T E
# 0 X
T O S T A R T
U S E
A. Procedure Up To Pulse Mode Selection
1.
2.
Turn on welding power source, if applicable.
The next repeating display scrolls into view.
Place the Mode Selector switch in the Automatic posi-
tion.
3.
4.
Place the Program/Run/Reset keyed switch in the Re-
set position, and then in the Program position. The
initial displays will be shown.
U S E
T O
I N C / D E C
B U T T O N S
C H E C K P A R A M E T E R S
When the repeating displays (explained in Section
5-1F) are shown, press Right/Increase.
2.
This display indicates that the Right/Increase and Left/
Decrease push buttons can be used to access the
displays and verify parameter values.
If the Process Selector switch is in the ac output posi-
tion, go to Step 5. If the Process Selector switch is in a
dc output position, go to Step 8.
5.
The display shows:
The next repeating display scrolls into view.
# 0 X
E N
B A L A N C E
X X %
C O N T R O L
E P X X %
U S E
T O
P A R A M E T E R
C H A N G E
S E L E C T
#
=
=
P R O G R A M
6.
If applicable, define the program number (see Section
5-1C). Define the electrode negative value for the ac
output square wave (see Section 4-3) as desired.
3.
This display explains the use of the Parameter Select
push button to change the program number. This al-
lows the creation of more than one program per mode.
The range for percentage of waveform in electrode
negative is 46% to 68%, in increments of 2%.
The next repeating display scrolls into view.
7.
8.
Press Right/Increase, and go to Step 8.
The display shows:
S E M I – A U T O M A T I C
H I G H
F R E Q U E N C Y
M O D E
X
> X X X X X X X X X <
4.
This display is present only in the Semi-Automatic
mode. The display indicates which of the five versions
of Semi-Automatic is active.
9.
Press Parameter Select to display the desired choice.
If the Process Selector switch is in the ac output posi-
tion, the choices are Start Only high frequency or
Continuous high frequency.
The next repeating display scrolls into view.
If the Process Selector switch is in a dc output position,
the choices are Start Only high frequency or Disabled
high frequency.
P R O C E S S
P O L A R I T Y
< X X .>
I S
10.
When the desired choice is shown, press Right/In-
crease to advance to the next display. The display
shows:
5.
This display indicates whether the Process Selector
switch is set for ac or dc output.
# 0 X
P R E F L O W
T I M E = X X .X
The first repeating display scrolls into view, and the se-
quence repeats.
OM-842 Page 22
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11.
12.
If applicable, define the program number (see Section
5-1C). Define the shielding gas preflow time as desired.
20.
To define pulse mode On, proceed as follows:
a. Be sure the desired means of defining pulse mode
has been selected according to Section 2-4.
The range for preflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
b. Use the Parameter Select push button to select
pulse mode On, and press Right/Increase to ad-
vance to the next display while ”On” is displayed.
Press Right/Increase, and the display shows:
c. If pulses are being defined as time values, go to
Section 5-2B.
# 0 X
S T A R T
L E V E L
T I M E = .X X X
A M P S = X X X .X
If pulses are being defined as a frequency, go to
Section 5-2C.
21.
To define pulse mode Off, proceed as follows:
13.
Define the start level time and amperage as desired.
a. Use the Parameter Select push button to select
pulse mode Off, and press Right/Increase while
”Off” is displayed. The display shows:
When properly used, start level eases arc starting by
allowing the use of an amperage value that is higher
than initial amperage for a short length of time.
The range for start level time is 0.0 to 15.0 seconds, in
increments of 0.1 seconds. The range for start level
amperage varies from 2.0 to 400 amperes, in incre-
ments of 1.0 amperes.
# 0 X
W E L D
A M P S = X X X .X
T I M E = X X X .X
14.
Press Right/Increase, and the display shows:
b. Define the weld current time and amperage values
as desired.
# 0 X
I N I T I A L
A M P S = X X X .X
The range for weld current time is 0.0 to 999.9 sec-
onds, in increments of 0.1 seconds. The range for
weld current amperage varies from 2.0 to 400 am-
peres, in increments of 1.0 amperes.
T I M E = X X .X
15.
16.
Define the initial current level time and amperage val-
ues as desired.
c. Press Right/Increase, and go to Section 5-2D.
The range for initial current level time is 0.0 to 25.0 sec-
onds, in increments of 0.1 seconds. The range for initial
current level amperage varies from 2.0 to 400 am-
peres, in increments of 1.0 amperes.
B. Procedure With Pulse Mode On, Pulses Defined
In Time Values
1.
The display shows:
Press Right/Increase, and the display shows:
# 0 X
W E L D
T I M E = X X X .X
# 0 X
I N I T I A L
S L O P E
T I M E = X X .X
a. Define the weld current time as desired.
The range for weld current time is 0.0 to 999.9 sec-
onds, in increments of 0.1 seconds.
17.
18.
Define the initial slope time as desired.
The range for initial slope time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
2.
Press Right/Increase, and the display shows:
Press Right/Increase, and the display shows:
# 0 X
P U L S E
P U L S E
A p K
A b K
= X X X .X
= X X X .X
* * P U L S E
M O D E
I S * *
> X X X <
3.
Define the ApK and AbK values as desired.
ApK defines the peak current during pulsing. AbK
defines the background current.
19.
Pressing Parameter Select toggles the display be-
tween pulse mode On and pulse mode Off. Three
possibilities exist at this point, as follows:
The ranges for both ApK and AbK are 2.0 to 400 am-
peres, in increments of 1.0 ampere.
Pulse mode On is desired and pulses are to be defined
as time spent in peak current and background current
(see Step 20).
4.
Press Right/Increase, and the display shows:
Pulse mode On is desired and pulses are to be defined
as a frequency, with peak current defined as a percent-
age of the total period (see Step 20).
# 0 X
P E A K
B A C K
T I M E
T I M E
= X .X X
= X .X X
Pulse mode Off is desired (see Step 21).
OM-842 Page 23
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5.
Define the peak time and background time values as
desired.
4.
5.
Press Right/Increase, and the display shows:
# 0 X
P U L S E S / S E C =
P U L S E P E A K
X X .X
X X
Peak time is the length of time the pulse is at the peak
level. Background time is the length of time the pulse is
at the background level.
%
=
The ranges for both peak and background times are
0.5 to 5.0 seconds, in increments of 0.5 seconds.
Define the pulse frequency per second and the per-
centage of pulse time to be spent in pulse peak as
desired.
6.
Press Right/Increase, and the display shows:
The range for pulse frequency is 0.1 to 10.0 pulses per
second, in increments of 0.1 pulses per second.
# 0 X
F R E Q U E N C Y
=
The range for percentage of pulse time to be spent in
pulse peak is 5% to 95%, in increments of 1%.
X X .X X
P U L S E S / S E C O N D
6.
7.
Press Right/Increase.
If the Process Selector switch is in the ac output posi-
tion, go to Section 5-2D. If the Process Selector switch
is in a dc output position, go to Step 7.
7.
8.
This display is for informational purposes. It indicates
the calculated frequency of pulses per second.
Press Right/Increase.
The display shows:
If the Process Selector switch is in the ac output posi-
tion, go to Section 5-2D. If the Process Selector switch
is in a dc output position, go to Step 9.
# 0 X
A V G
C U R R E N T
A M P S
=
X X X .X
9.
The display shows:
8.
9.
This display is for informational purposes. It indicates
the calculated average current during pulsing.
# 0 X
A V G
C U R R E N T
A M P S
=
X X X .X
Press Right/Increase, and go to Section 5-2D.
D. Procedure Following Pulse Mode Definition
10.
11.
This display is for informational purposes. It indicates
the calculated average current during pulsing.
1.
The display shows:
Press Right/Increase, and go to Section 5-2D.
# 0 X
F I N A L
S L O P E
T I M E = X X .X
C. Procedure With Pulse Mode On, Pulses Defined
As A Frequency
2.
3.
Define the final slope time as desired.
1.
The display shows:
The range for final slope time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
# 0 X
W E L D
T I M E = X X X .X
Press Right/Increase, and the display shows:
# 0 X
F I N A L
A M P S = X X X .X
T I M E = X X .X
a. Define the weld current time as desired.
The range for weld current time is 0.0 to 999.9 sec-
onds, in increments of 0.1 seconds.
4.
5.
Define the final current time and amperage as desired.
The range for final current level time is 0.0 to 25.0 sec-
onds, in increments of 0.1 seconds. The range for final
level amperage varies from 2.0 to 400 amperes, in in-
crements of 1.0 amperes.
2.
Press Right/Increase, and the display shows:
# 0 X
P U L S E
P U L S E
A p K
A b K
= X X X .X
= X X X .X
Press Right/Increase, and the display shows:
# 0 X
P O S T F L O W
T I M E = X X .X
3.
Define the ApK and AbK values as desired.
ApK defines the peak current during pulsing. AbK
defines the background current.
6.
Define the shielding gas postflow time as desired.
The ranges for both ApK and AbK are 2.0 to 400 am-
peres, in increments of 1.0 ampere.
The range for postflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
OM-842 Page 24
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7.
Press Right/Increase, and the display shows:
5-3. Semi-Automatic Mode
If needed, see Section 5-1B for
information on selecting and defining
a parameter.
# 0 X W I R E – F E E D
D E L A Y X X .X
S T A R T
S E C.
NOTE
NOTE
=
Weld output options, such as the use
of pulsing, high frequency, and ac or
dc output, affect how a program is
entered in the Semi-Automatic
mode. Be sure to follow all applicable
steps, and only the applicable steps,
as determined by the selected
options.
8.
Define the wire feed start delay as desired.
Wire feed start delay is the amount of time between the
end of initial current and when the wire feed user relay
(see Section 2-3) changes states. A delay time of 0
means the wire feed relay changes state immediately
at the end of initial current. A delay time of 3.5 means
the relay changes state 3.5 seconds after the end of ini-
tial current.
This section covers program entry in
all five Semi-Automatic modes.
Differences between one mode and
another are stated. Be sure the
desired Semi-Automatic mode has
been defined on DIP switch SW1
(see Section 2-4) before using the
following procedure to enter a
program.
NOTE
The wire feed relay change cannot be delayed beyond
the end of weld current. When weld current ends, the
wire feed relay changes states whether or not the de-
fined start delay time has elapsed.
The range for start delay time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
9.
Press Right/Increase, and the display shows:
A. Procedure Up To Pulse Mode Selection
# 0 X W I R E – F E E D
D E L A Y X X .X
S T O P
S E C.
1.
2.
Turn on welding power source, if applicable.
=
Place the Mode Selector switch in the Semi-Automatic
position.
3.
4.
Place the Program/Run/Reset keyed switch in the Re-
set position, and then in the Program position. The
initial displays will be shown.
10.
Define the wire feed stop delay as desired.
Wire feed stop delay is the amount of time between the
end of weld current and when the wire feed user relay
(see Section 2-3) change states. A delay time of 0
means the wire feed relay changes state immediately
at the end of weld current. A delay time of 7.0 means
the relay changes state 7.0 seconds after the end of
weld current.
When the repeating displays (explained in Section
5-1F) are shown, press Right/Increase.
If the Process Selector switch is in the ac output posi-
tion, go to Step 5. If the Process Selector switch is in a
dc output position, go to Step 8.
5.
The display shows:
The wire feed relay change cannot be delayed beyond
the end of postflow. When postflow ends, the wire feed
relay changes states whether or not the defined stop
delay time has elapsed.
# 0 X
E N
B A L A N C E
X X %
C O N T R O L
E P X X %
=
=
The range for stop delay time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
6.
If applicable, define the program number (see Section
5-1C). Define the electrode negative value for the ac
output square wave (see Section 4-3) as desired.
11.
Press Right/Increase, and the display shows:
The range for percentage of waveform in electrode
negative is 46% to 68%, in increments of 2%.
* * * * * *
D R Y R U N
T O
* * * * * *
S T A R T
7.
8.
Press Right/Increase, and go to Step 8.
The display shows:
U S E R E M O T E
12.
13.
If desired, press Start/Increase on the Remote Pend-
ant to carry out a dry run of the program (see Section
5-7 for information on the dry run feature). To place the
microprocessor control in the Ready condition, press
Right/Increase.
H I G H
F R E Q U E N C Y
> X X X X X X X X X <
9.
Press Parameter Select to display the desired choice.
In the Ready condition the microprocessor control is
ready to have another program entered or to execute a
program. For information on executing a program, refer
to Section 6.
If the Process Selector switch is in the ac output posi-
tion, the choices are Start Only high frequency or
Continuous high frequency.
OM-842 Page 25
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If the Process Selector switch is in a dc output position,
the choices are Start Only high frequency or Disabled
high frequency.
The range for initial slope time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
18.
19.
Press Right/Increase, and the display shows:
10.
When the desired choice is shown, press Right/In-
crease to advance to the next display. The display
shows:
* * P U L S E
M O D E
I S * *
> X X <
# 0 X
P R E F L O W
T I M E = X X .X
Pressing Parameter Select toggles the display be-
tween pulse mode On and pulse mode Off. Three
possibilities exist at this point, as follows:
11.
If applicable, define the program number (see Section
5-1C). Define the shielding gas preflow time as desired.
Pulse mode On is desired and pulses are to be defined
as time spent in peak current and background current
(see Step 20).
The range for preflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
Pulse mode On is desired and pulses are to be defined
as a frequency, with peak current defined as a percent-
age of the total period (see Step 20).
12.
Press Right/Increase, and the display shows:
Pulse mode Off is desired (see Step 21).
# 0 X
S T A R T
L E V E L
20.
To define pulse mode On, proceed as follows:
T I M E = .X X X
A M P S = X X X .X
a. Be sure the desired means of defining pulse mode
has been selected according to Section 2-4.
b. Use the Parameter Select push button to select
pulse mode On, and press Right/Increase to ad-
vance to the next display while ”On” is displayed.
13.
Define the start level time and amperage as desired.
When properly used, start level eases arc starting by
allowing the use of an amperage value that is higher
than initial amperage for a short length of time.
c. If pulses are being defined as time values, go to
Section 5-3B.
The range for start level time is 0.0 to 15.0 seconds, in
increments of 0.1 seconds. The range for start level
amperage varies from 2.0 to 400 amperes, in incre-
ments of 1.0 amperes.
If pulses are being defined as a frequency, go to
Section 5-3C.
21.
To define pulse mode Off, proceed as follows:
14.
Press Right/Increase, and the display shows:
a. For Semi-Automatic 1 and 5 modes:
a. Use the Parameter Select push button to select
pulse mode Off, and press Right/Increase while
”Off” is displayed. The display shows:
# 0 X
I N I T I A L
A M P S = X X X .X
# 0 X
W E L D
T I M E = X X .X
A M P S = X X X .X
b. For Semi-Automatic 2, 3, and 4 modes:
b. Define the weld current as desired.
The range for weld current varies from 2.0 to 400.0
amps, in increments of 1.0 amperes.
# 0 X
I N I T I A L
A M P S = X X X .X
c. Press Right/Increase. Go to Section 5-3D if pro-
gramming in Semi-Automatic 1 or 5 modes. Go to
Section 5-3E if programming in Semi-Automatic 2,
3, or 4 modes.
15.
Define the initial current level time (if applicable) and
amperage as desired.
B. Procedure With Pulse Mode On, Pulses Defined
In Time Values
The range for initial current level time is 0.0 to 25.0 sec-
onds, in increments of 0.1 seconds. The range for initial
current level amperage varies from 2.0 to 400 am-
peres, in increments of 1.0 amperes.
1.
The display shows:
16.
Press Right/Increase, and the display shows:
# 0 X
P U L S E
P U L S E
A p K
A b K
= X X X .X
= X X X .X
# 0 X
I N I T I A L
S L O P E
T I M E = X X .X
2.
Define the ApK and AbK values as desired.
ApK defines the peak current during pulsing. AbK
defines the background current.
17.
Define the initial slope time as desired.
OM-842 Page 26
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The ranges for both ApK and AbK are 2.0 to 400 am-
peres, in increments of 1.0 ampere.
3.
4.
Press Right/Increase, and the display shows:
3.
Press Right/Increase, and the display shows:
# 0 X
P U L S E S / S E C =
P U L S E P E A K
X X .X
X X
%
=
# 0 X
P E A K
B A C K
T I M E
T I M E
= X .X X
= X .X X
Define the pulse frequency per second and the per-
centage of pulse time to be spent in pulse peak as
desired.
4.
Define the peak time and background time as desired.
The range for pulse frequency is 0.1 to 10.0 pulses per
second, in increments of 0.1 pulses per second.
Peak time is the length of time the pulse is at the peak
level. Background time is the length of time the pulse is
at the background level.
The range for percentage of pulse time to be spent in
pulse peak is 5% to 95%, in increments of 1%.
The ranges for both peak and background times are
0.5 to 5.0 seconds, in increments of 0.5 seconds.
5.
6.
Press Right/Increase.
If the Process Selector switch is in the ac output posi-
tion, go to Section 5-3D if programming in
Semi-Automatic 1 or 5 modes; go to Section 5-3E if pro-
gramming in Semi-Automatic 2, 3, or 4 modes.
5.
Press Right/Increase, and the display shows:
# 0 X
F R E Q U E N C Y
=
If the Process Selector switch is in a dc output position,
go to Step 6.
X X .X X
P U L S E S / S E C O N D
The display shows:
6.
7.
This display is for informational purposes. It indicates
the calculated frequency of pulses per second.
# 0 X
A V G
C U R R E N T
A M P S
=
Press Right/Increase.
X X X .X
If the Process Selector switch is in the ac output posi-
tion, go to Section 5-3D if programming in
Semi-Automatic 1 or 5 modes; go to Section 5-3E if pro-
gramming in Semi-Automatic 2, 3, or 4 modes.
7.
8.
This display is for informational purposes. It indicates
the calculated average current during pulsing.
If the Process Selector switch is in a dc output position,
go to Step 8.
Press Right/Increase. Go to Section 5-3D if program-
ming in Semi-Automatic 1 or 5 modes. Go to Section
5-3E if programming in Semi-Automatic 2, 3, or 4
modes.
8.
The display shows:
# 0 X
A V G
C U R R E N T
A M P S
=
D. Procedure Following Pulse Mode Definition For
Semi-Automatic 1 And 5 Modes
X X X .X
1.
The display shows:
9.
This display is for informational purposes. It indicates
the calculated average current during pulsing.
# 0 X
F I N A L
S L O P E
10.
Press Right/Increase. Go to Section 5-3D if program-
ming in Semi-Automatic 1 or 5 modes. Go to Section
5-3E if programming in Semi-Automatic 2, 3, or 4
modes.
T I M E = X X .X
2.
Define the final slope time as desired.
The range for final slope time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds. Define the final slope time
as desired.
C. Procedure With Pulse Mode On, Pulses Defined
As A Frequency
1.
The display shows:
3.
Press Right/Increase, and the display shows:
# 0 X
P U L S E
P U L S E
A p K
A b K
= X X X .X
= X X X .X
# 0 X
F I N A L
A M P S = X X X .X
T I M E = X X .X
2.
Define the ApK and AbK values as desired.
4.
Define the final current time and amperage as desired.
ApK defines the peak current during pulsing. AbK
defines the background current.
The range for final current level time is 0.0 to 25.0 sec-
onds, in increments of 0.1 seconds. The range for final
level amperage varies from 2.0 to 400 amperes, in in-
crements of 1.0 amperes.
The ranges for both ApK and AbK are 2.0 to 400 am-
peres, in increments of 1.0 ampere.
OM-842 Page 27
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5.
Press Right/Increase, and the display shows:
12.
13.
If desired, press Start/Increase on the Remote Pend-
ant to carry out a dry run of the program (see Section
5-7 for information on the dry run feature). To place the
microprocessor control in the Ready condition, press
Right/Increase.
# 0 X
P O S T F L O W
T I M E = X X .X
In the Ready condition the microprocessor control is
ready to have another program entered or to execute a
program. For information on executing a program, see
Section 6.
6.
7.
Define the shielding gas postflow time as desired.
The range for postflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
E. Procedure Following Pulse Mode Definition For
Semi-Automatic 2, 3, And 4 Modes
Press Right/Increase, and the display shows:
1.
The display shows:
# 0 X W I R E – F E E D
D E L A Y X X .X
S T A R T
S E C.
# 0 X
F I N A L
S L O P E
=
T I M E = X X .X
2.
3.
Define the final slope time as desired.
8.
Define the wire feed start delay as desired.
The range for final slope time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds. Define the final slope time
as desired.
Wire feed start delay is the amount of time between the
end of initial current and when the wire feed user relay
(see Section 2-3) changes states. A delay time of 0
means the wire feed relay changes state immediately
at the end of initial current. A delay time of 3.5 means
the relay changes state 3.5 seconds after the end of ini-
tial current.
Press Right/Increase, and the display shows:
a. For Semi-Automatic 2 and 3 modes:
# 0 X
F I N A L
The wire feed relay change cannot be delayed beyond
the end of weld current. When weld current ends, the
wire feed relay changes states whether or not the de-
fined start delay time has elapsed.
A M P S = X X X .X
b. For Semi-Automatic 4 mode:
The range for start delay time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
# 0 X
F I N A L
A M P S = X X X .X
9.
Press Right/Increase, and the display shows:
T I M E = X X .X
# 0 X W I R E – F E E D
D E L A Y X X .X
S T O P
S E C.
4.
5.
Define the final current time (if applicable) and amper-
age as desired.
=
The range for final current level time is 0.0 to 25.0 sec-
onds, in increments of 0.1 seconds. The range for final
level amperage varies from 2.0 to 400 amperes, in in-
crements of 1.0 amperes.
10.
Define the wire feed stop delay as desired.
Wire feed stop delay is the amount of time between the
end of weld current and when the wire feed user relay
(see Section 2-3) changes states. A delay time of 0
means the wire feed relay changes state immediately
at the end of weld current. A delay time of 7.0 means
the relay changes state 7.0 seconds after the end of
weld current.
Press Right/Increase, and the display shows:
S T O P
B U T T O N
D E T E C T
> X X X X X X X X X X <
The wire feed relay change cannot be delayed beyond
the end of postflow. When postflow ends, the wire feed
relay changes states whether or not the defined stop
delay time has elapsed.
6.
Pressing Parameter Select toggles the display be-
tween stop button detect Enabled and Disabled. When
the desired choice is shown, press Right/Increase to
advance to the next display. The display shows:
The range for stop delay time is 0.0 to 25.0 seconds, in
increments of 0.1 seconds.
# 0 X
P O S T F L O W
T I M E = X X .X
11.
Press Right/Increase, and the display shows:
* * * * * *
D R Y R U N
* * * * * *
S T A R T
7.
Define the shielding gas postflow time as desired.
U S E
R E M O T E T O
The range for postflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
OM-842 Page 28
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8.
9.
Press Right/Increase. The microprocessor control will
enter the Ready condition.
If the Process Selector switch is in a dc output position,
the choices are Start Only high frequency or Disabled
high frequency.
In the Ready condition the microprocessor control is
ready to have another program entered or to execute a
program. For information on executing a program, see
Section 6.
10.
When the desired choice is shown, press Right/In-
crease to advance to the next display. The display
shows:
# 0 X
P R E F L O W
5-4. Manual GTAW Mode
T I M E = X X .X
If needed, see Section 5-1B for
NOTE
NOTE
information on selecting and defining
a parameter.
11.
If applicable, define the program number (see Section
5-1C). Define the shielding gas preflow time as desired.
The range for preflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
Weld output options, such as the use
of pulsing, high frequency, and ac or
dc output, affect how a program is
entered in the Manual GTAW mode.
Be sure to follow all applicable steps,
and only the applicable steps, as
determined by the selected options.
12.
Press Right/Increase, and the display shows:
# 0 X
S T A R T
L E V E L
T I M E = .X X X
A M P S = X X X .X
13.
Define the start level time and amperage as desired.
A. Procedure Up To Pulse Mode Selection
When properly used, start level eases arc starting by
allowing the use of an amperage value that is higher
than initial amperage for a short length of time.
1.
2.
Turn on welding power source, if applicable.
Place the Mode Selector switch in the Manual GTAW
position.
The range for start level time is 0.0 to 15.0 seconds, in
increments of 0.1 seconds. The range for start level
amperage varies from 2.0 to 400 amperes, in incre-
ments of 1.0 amperes.
3.
4.
Place the Program/Run/Reset keyed switch in the Re-
set position, and then in the Program position. The
initial displays will be shown.
14.
15.
Press Right/Increase, and the display shows:
When the repeating displays (explained in Section
5-1F) are shown, press Right/Increase.
* * P U L S E
M O D E
I S * *
If the Process Selector switch is in the ac output posi-
tion, go to Step 5. If the Process Selector switch is in a
dc output position, go to Step 8.
> X X <
5.
The display shows:
Pressing Parameter Select toggles the display be-
tween pulse mode On and pulse mode Off. Three
possibilities exist at this point, as follows:
# 0 X
E N
B A L A N C E
X X %
C O N T R O L
E P X X %
Pulse mode On is desired and pulses are to be defined
as time spent in peak current and background current
(see Step 16).
=
=
Pulse mode On is desired and pulses are to be defined
as a frequency, with peak current defined as a percent-
age of the total period (see Step 16).
6.
If applicable, define the program number (see Section
5-1C). Define the electrode negative value for the ac
output square wave (see Section 4-3) as desired.
Pulse mode Off is desired (see Step 17).
The range for percentage of waveform in electrode
negative is 46% to 68%, in increments of 2%.
16.
To define pulse mode On, proceed as follows:
a. Be sure the desired means of defining pulse mode
has been selected according to Section 2-4.
7.
8.
Press Right/Increase, and go to Step 8.
The display shows:
b. Use the Parameter Select push button to select
pulse mode On, and press Right/Increase to ad-
vance to the next display while ”On” is displayed.
H I G H
F R E Q U E N C Y
c. If pulses are being defined as time values, go to
Section 5-4B.
> X X X X X X X X X <
If pulses are being defined as a frequency, go to
Section 5-4C.
9.
Press Parameter Select to display the desired choice.
17.
To define pulse mode Off, proceed as follows:
If the Process Selector switch is in the ac output posi-
tion, the choices are Start Only high frequency or
Continuous high frequency.
a. Use the Parameter Select push button to select
pulse mode Off, and press Right/Increase while
”Off” is displayed. The display shows:
OM-842 Page 29
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2.
3.
Define the ApK and AbK values as desired.
# 0 X
W E L D
ApK defines the peak current during pulsing. AbK
defines the background current.
A M P S = X X X .X
The ranges for both ApK and AbK are 2.0 to 400 am-
peres, in increments of 1.0 ampere.
b. Define the weld current as desired.
Press Right/Increase, and the display shows:
The range for weld current varies from 2.0 to 400.0
amps, in increments of 1.0 amperes.
c. Press Right/Increase, and go to Section 5-4D.
# 0 X
P U L S E S / S E C =
P U L S E P E A K
X X .X
X X
B. Procedure With Pulse Mode On, Pulses Defined
In Time Values
%
=
1.
The display shows:
4.
Define the pulse frequency per second and the per-
centage of pulse time to be spent in pulse peak as
desired.
# 0 X
P U L S E
P U L S E
A p K
A b K
= X X X .X
= X X X .X
The range for pulse frequency is 0.1 to 10.0 pulses per
second, in increments of 0.1 pulses per second.
The range for percentage of pulse time to be spent in
pulse peak is 5% to 95%, in increments of 1%.
2.
Define the ApK and AbK values as desired.
ApK defines the peak current during pulsing. AbK
defines the background current.
5.
Press Right/Increase, and go to Section 5-4D.
The ranges for both ApK and AbK are 2.0 to 400 am-
peres, in increments of 1.0 ampere.
D. Procedure Following Pulse Mode Definition
1.
The display shows:
3.
Press Right/Increase, and the display shows:
# 0 X
P O S T F L O W
# 0 X
P E A K
B A C K
T I M E
T I M E
= X .X X
= X .X X
T I M E = X X .X
4.
Define the peak time and background time as desired.
2.
3.
Define the shielding gas postflow time as desired.
Peak time is the length of time the pulse is at the peak
level. Background time is the length of time the pulse is
at the background level.
The range for postflow is 0.0 to 25.0 seconds, in incre-
ments of 0.1 seconds.
Press Right/Increase, and the display shows:
The ranges for both peak and background times are
0.5 to 5.0 seconds, in increments of 0.5 seconds.
C U R R E N T
C O N T R O L
5.
Press Right/Increase, and the display shows:
< X X X X X X X >
# 0 X
F R E Q U E N C Y
=
X X .X X
P U L S E S / S E C O N D
4.
Pressing Parameter Select toggles the display be-
tween Panel and Remote. When Remote is defined,
weld amperage can be varied by a remote amperage
control device up to the user-defined weld current level.
When Panel is defined, weld amperage is the value de-
fined as weld current.
6.
7.
This display is for informational purposes. It indicates
the calculated frequency of pulses per second.
Press Right/Increase, and go to Section 5-4D.
Whichever option is showing when this display is ex-
ited will be in effect. Use the Parameter Select push
button to display the desired option (Panel or Remote).
C. Procedure With Pulse Mode On, Pulses Defined
As A Frequency
1.
The display shows:
5.
6.
Press Right/Increase. The microprocessor control will
enter the Ready condition.
# 0 X
P U L S E
P U L S E
A p K
A b K
= X X X .X
= X X X .X
In the Ready condition the microprocessor control is
ready to have another program entered or to execute a
program. For information on executing a program, see
Section 6.
OM-842 Page 30
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5-5. SMAW Mode
# 0 X
A R C
C O N T R O L
0 0 0
If needed, see Section 5-1B for
P E R C E N T A G E
=
%
NOTE
information on selecting and defining
a parameter.
13.
14.
Arc control increases short-circuit amperage to help
start an arc or make vertical or overhead welds.
1.
2.
3.
Turn on welding power source, if applicable.
Place the Mode Selector switch in the SMAW position.
The range for arc control is 0% to 100%, in increments
of 1%.
Place the Program/Run/Reset keyed switch in the Re-
set position, and then in the Program position. The
initial displays will be shown.
Press Right/Increase, and the display shows:
4.
When the repeating displays (explained in Section
5-1F) are shown, press Right/Increase.
C U R R E N T
C O N T R O L
< X X X X X X X >
If the Process Selector switch is in the ac output posi-
tion, go to Step 5. If the Process Selector switch is in a
dc output position, go to Step 8.
15.
Pressing Parameter Select toggles the display be-
tween Panel and Remote. When Remote is defined,
weld amperage can be varied by a remote amperage
control device up to the user-defined weld current level.
When Panel is defined, weld amperage is the value de-
fined as weld current.
5.
The display shows:
# 0 X
E N
B A L A N C E
X X %
C O N T R O L
E P X X %
=
=
Whichever option is showing when this display is ex-
ited will be in effect. Use the Parameter Select push
button to display the desired option (Panel or Remote).
6.
If applicable, define the program number (see Section
5-1C). Define the electrode negative value for the ac
output square wave (see Section 4-3) as desired.
16.
17.
Press Right/Increase. The microprocessor control will
enter the Ready condition.
The range for percentage of waveform in electrode
negative is 46% to 68%, in increments of 2%.
In the Ready condition, the microprocessor control is
ready to have another program entered or to execute a
program. For information on executing a program, see
Section 6.
7.
8.
Press Right/Increase, and go to Step 8.
The display shows:
5-6. Editing A Program
# 0 X
S T A R T
L E V E L
To edit an existing program, carry out the following:
T I M E = .X X X
A M P S = X X X .X
1.
2.
Turn on welding power source, if applicable.
Use the Mode Selector switch to select the mode of the
program to be edited.
9.
If applicable, define the program number (see Section
5-1C). Define the start level time and amperage as de-
sired.
3.
4.
Place the Program/Run/Reset keyed switch in the Pro-
gram position.
When properly used, start level eases arc starting by
allowing the use of an amperage value that is higher
than initial amperage for a short length of time.
When the repeating displays are shown, press the
Right/Increase or Left/Decrease push button until the
display to be edited is shown.
The range for start level time is 0.0 to 15.0 seconds, in
increments of 0.1 seconds. The range for start level
amperage varies from 2.0 to 400.0 amps, in increments
of 1.0 amperes.
5.
6.
Edit the desired parameter(s). If needed, see Section
5-1B for information on selecting and defining parame-
ters. See Section 5-1C for information on changing the
program number in a display to access multiple pro-
grams.
10.
Press Right/Increase, and the display shows:
Continue accessing displays and editing parameters
until editing is complete. The newly entered parame-
ters become a part of the program as soon as they are
entered.
# 0 X
W E L D
A M P S = X X X .X
7.
8.
To lock out program changes and prepare for program
execution, place the Program/Run/Reset keyed switch
in the Run position.
11.
12.
Define the weld current as desired.
The range for weld current varies from 2.0 to 400.0
amps, in increments of 1.0 amperes.
To prepare for program execution while remaining in
Program, press Right/Increase or Left/Decrease until
the Ready condition is active (see Section 5-1F).
Press Right/Increase, and the display shows:
OM-842 Page 31
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would be assigned to position three. A reset would be as-
signed to position four to indicate the end of the linked
programs.
5-7. Dry Run Feature
The Dry Run feature allows a program to be verified by execut-
ing it without actually establishing an arc. All timing and contact
closures are performed without gas, high frequency, or power
source contactor being activated.
When the Link mode is entered, three displays are repeated in
sequence. This indicates that the Link Ready condition is ac-
tive. These displays must be present in order to start execution
of the linked programs.
The Dry Run feature is only available in the Automatic mode
and Semi-Automatic 1 or 5 modes. When used in the Semi-Au-
tomatic 1 or 5 modes, the weld time continues to increment
until the Start/Increase on the Remote Pendant is pressed.
To link programs, proceed as follows:
1.
2.
3.
Be sure one of the proper modes is selected (see Im-
portant block at beginning of this section).
To use the Dry Run feature, proceed as follows:
Place the Program/Run/Reset keyed switch in the Pro-
gram position.
1.
2.
Access the Dry Run display.
Call up the following display (this is one of the repeating
displays explained in Section 5-1F).
Press Start/Increase on the Remote Pendant to begin
the dry run execution.
3.
The microprocessor control will perform a dry run of the
program. The dry run stops automatically when the
programmed postflow time elapses. To stop the dry run
before completion, press the Stop push button.
P R O G R A M
R E M O T E
# 0 X
T O S T A R T
U S E
5-8. Stop Watch Feature
4.
Press Parameter Select to increase the program num-
ber beyond 4. The following repeating Link mode
displays appear:
The Stop Watch feature is a part of Dry Run when Dry Run is
used in the Automatic mode. Stop Watch allows the operator to
define the end of weld time by pressing the Start/Increase push
button. This enables the operator to observe fixturing during a
dry run and define the end of weld time relative to actual posi-
tions.
P R O G R A M
U S E
” L I N K ”
M O D E
R E M O T E
T O
S T A R T
To use the Stop Watch feature, proceed as follows:
1.
2.
3.
Enter a 0 (zero) for weld time when entering a program
in the Automatic mode.
U S E
I N C / D E C
B U T T O N S
T H E L I N K S
Carry out a dry run of the entered program (see Section
5-7).
T O
C H A N G E
When the desired end of weld time is reached, press
Start/Increase on the Remote Pendant. The time dis-
played when the push button is pressed becomes the
weld time value in the program and remains so until
changed.
U S E
T O
P A R A M E T E R
E X I T ” L I N K ”
S E L E C T
M O D E
5-9. Linking Programs
P R O C E S S
P O L A R I T Y
< X X .>
I S
The Link feature is only available in
NOTE
the following modes: Automatic,
Semi-Automatic 1, and Semi-
Automatic 5.
5.
Press Right/Increase, and the display shows:
Existing programs in the required modes can be linked togeth-
er so that the next program in sequence begins when
Start/Increase is pressed on the Remote Pendant. Up to four
programs can be linked. All linked programs must be in the
same mode of operation. The first program desired in the chain
of programs is assigned to position one, the second desired
program is assigned to position two, etc. A reset is assigned to
the Link position following the last program to signal the end of
the linked programs.
L I N K
I S
P O S I T I O N
X X X X X X X
X X
6.
7.
The Link position (1 through 4) is indicated in the upper
right corner. The second line indicates what function
(either a program number or Reset) is assigned to the
position.
If four programs are linked together, it
is not necessary for the user to
NOTE
To change the number of the Link position, select it and
press either Right/Increase or Left/Decrease to
change the value as desired. As the Link position num-
bers change, the function currently assigned to that
position is displayed in the second line.
assign
a
reset.
A
reset is
permanently assigned to the fifth
Link position.
For example, to run program 2, then program 1, and finally pro-
gram 4, program 2 would be assigned to link position one,
program 1 would be assigned to position two and program 4
8.
To change the function assigned to a Link position, se-
lect the function and press either Right/Increase or
Left/Decrease to change the value.
OM-842 Page 32
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Reset follows Program Number 04. To assign Reset to
a Link position, select the function and press Right/In-
crease repeatedly to go beyond Program Number 04.
To assign a number when Reset is displayed, select
Reset and press Left/Decrease.
P R O G R A M
R E M O T E
# 0 X
T O S T A R T
U S E
9.
Repeat Steps 7 and 8 as needed to define the desired
function for each Link position being used.
3.
Press Parameter Select to increase the program num-
ber beyond 4. The following repeating Link mode
display appears:
10.
Select the Link Position number in the upper right cor-
ner of the display, and press Right/Increase or
Left/Decrease to display the number of the first Link po-
sition to be executed when the program is executed.
P R O G R A M
U S E
” L I N K ”
M O D E
R E M O T E
T O
S T A R T
The Link position shown when the
NOTE
Link mode is exited is the first
position executed when the Link
programs are run. Be sure the
desired Link position is showing
before exiting the Link mode.
4.
Press Parameter Select to enter the Combine mode.
The following repeating Combine mode displays ap-
pear:
” C O M B I N E ”
M O D E
11.
12.
Press Right/Increase when there are no parameters
selected in the Link Position display. The repeating
Link mode displays will appear.
U S E
R E M O T E
T O
S T A R T
Press Parameter Select while the repeating displays
are shown to exit the Link mode. The display shows:
U S E
T O
I N C / D E C
B U T T O N S
” C O M B I N E ”
U S E R E M O T E
M O D E
T O S T A R T
E N T E R
C H A N G E S
U S E
T O
P A R A M E T E R
S E L E C T
13.
If desired, use the Combine mode as explained in Sec-
tion 5-10. To exit the Combine mode without using it,
press Parameter Select while this display is shown.
The microprocessor control will enter the Ready condi-
tion.
E X I T ” C O M B I N E ”
P R O C E S S
P O L A R I T Y
< X X .>
I S
5-10. Combining Programs
The Combine feature is only
NOTE
available in the following modes:
Automatic, Semi-Automatic 1, and
Semi-Automatic 5.
5.
Press Right/Increase, and the display shows:
The Combine feature uses parameters from several programs
to create a single multi-slope weld program. The first program
defines preflow, initial amperage, initial to weld amperage
slope, and the weld amperage. Following specified programs
provide weld to weld slopes and weld times. The weld to weld
slopes are calculated by the microprocessor control. The last
program provides the final slope, and final amperage and post-
flow values. This is useful in applications using multiple
non-stop passes, such as pipe-welding with the use of a seam-
tracker.
C O M B I N E
P O S I T I O N
X X
I S X X X X X X X
6.
7.
The Combine position (1 through 4) is indicated in the
upper right corner. The second line indicates what
function (either a program number or Reset) is as-
signed to the position.
To change the number of the Combine position, select
it and press either Right/Increase or Left/Decrease to
change the value as desired. As the Combine position
numbers change, the function currently assigned to
that position will be displayed in the second line.
When the Combine mode is entered, three displays are re-
peated in sequence, indicating that the Combine Ready
condition is active. These displays must be present in order to
start execution of the combined programs.
To combine programs, proceed as follows:
8.
To change the function assigned to a Combine posi-
tion, select the function and press either Right/Increase
or Left/Decrease to change the value.
1.
Be sure one of the proper modes is selected (see Im-
portant block at beginning of this section).
2.
Call up the following display (this is one of the repeating
displays explained in Section 5-1F).
Reset follows Program Number 04. To assign Reset to
a Combine position, select the function and press
OM-842 Page 33
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Right/Increase repeatedly to go beyond Program
Number 04. To assign a number when Reset is dis-
played, select Reset and press Left/Decrease.
*
D R Y R U N
” C O M B I N E ”
T O S T A R T
*
U S E R E M O T E
If four programs are combined
NOTE
together, it is not necessary for the
user to assign a reset. A reset is
permanently assigned to the fifth
Combine position.
11.
If desired, press Start/Increase on the Remote Pend-
ant to carry out a dry run of the combined program (see
Section 5-7 for information on the dry run feature). To
exit the Combine mode, press Right/Increase, and
then Parameter Select when the repeating Combine
mode displays are shown. The microprocessor control
will enter the Ready condition.
9.
Repeat Steps 7 and 8 as needed to define the desired
function for each Combine position being used.
10.
Press Right/Increase when there are no parameters
selected in the Combine Position display. The display
shows:
SECTION 6 – SEQUENCE OF OPERATION
d. During the Weld Time portion of the program, the
Start/Increase or Decrease push buttons may be
pressed and held to modify the weld current level
within the defined amperage adjustment limits (see
Section 2-4). The programmed values will not be
affected.
6-1. Gas Tungsten Arc Welding (GTAW) In
The Automatic Mode
e. At any time, the Stop push button may be pressed
to end the weld sequence prematurely and send
the program to postflow.
1.
2.
Be sure welding power source and related equipment
are installed as instructed in their respective Owner’s
Manuals.
f. After postflow is timed out, the control unit returns
to the Ready condition and waits for the next clo-
sure of the Start/Increase push button. If
Start/Increase is pressed during postflow, the pro-
gram restarts the weld sequence from the
beginning without preflow timing.
Be sure desired weld program (or programs) has been
entered.
3.
4.
Place Mode Selector switch in Automatic position.
Select and prepare tungsten electrode according to
welding power source Owner’s Manual.
6-2. Gas Tungsten Arc Welding (GTAW) In
The Semi-Automatic Modes
5.
6.
7.
8.
9.
Insert electrode into torch.
Wear dry insulating gloves and clothing.
Connect work clamp to clean, bare metal at workpiece.
Turn on shielding gas supply at source.
Wear welding helmet with proper filter lens according to
ANSI Z49.1.
A. Shared Initial Procedure
1.
Be sure welding power source and related equipment
are installed as instructed in their respective Owner’s
Manuals.
10.
11.
Energize welding power source.
Begin welding, observing the following:
2.
3.
4.
5.
Be sure desired weld program (or programs) has been
entered.
a. Be sure the desired program is active before ex-
ecuting a program. The active program is indicated
in the applicable repeating display (see Section
5-1F). To select a different program, press Param-
eter Select while the repeating displays are shown.
This increases the program number.
Be sure desired Semi-Automatic mode is selected on
DIP switch SW1 (see Section 2-4).
Place Mode Selector switch in Semi-Automatic posi-
tion.
b. When the unit is in the Ready condition (see Sec-
tion 5-1F), momentarily press Start/Increase to
begin the weld sequence.
Select and prepare tungsten electrode according to
welding power source Owner’s Manual.
6.
7.
8.
9.
Insert electrode into torch.
c. The voltage and amperage meters display the
weld voltage and amperage while welding. The
weld sequence displays are shown on the digital
display, with time values changing to reflect events
being carried out.
Wear dry insulating gloves and clothing.
Connect work clamp to clean, bare metal at workpiece.
Turn on shielding gas supply at source.
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10.
11.
Wear welding helmet with proper filter lens according to
ANSI Z49.1.
during postflow, the program restarts the weld se-
quence from the beginning without preflow timing.
Be sure applicable remote control device is connected
as follows:
C. Operation Procedures For Semi-Automatic 2
Mode
a. Semi-Automatic 1 Mode:
1.
When the unit is in the Ready condition (see Section
5-1F), momentarily press Start/Increase to begin the
weld sequence. After arc initiation at initial current, the
control unit maintains the programmed initial current
value.
Connect Remote Pendant to Remote 4 receptacle
RC2.
b. Semi-Automatic 2 Mode:
Connect Remote Pendant to Remote 4 receptacle
RC2.
2.
3.
Start/Increase must be pressed to signal the end of ini-
tial time and the beginning of initial slope. Following
initial slope, the control unit maintains Weld Time cur-
rent.
c. Semi-Automatic 3 Mode:
Connect Remote Pendant to Remote 4 receptacle
RC2.
Start/Increase must be pressed to signal the end of
Weld Time and the beginning of final slope. Following
final slope, the control unit maintains the arc at the final
current level
d. Semi-Automatic 4 Mode:
Connect Remote Pendant to Remote 4 receptacle
RC2.
4.
5.
Start/Increase must be pressed to signal the end of fi-
nal current and the beginning of postflow.
e. Semi-Automatic 5 Mode:
After postflow is timed out, the control unit returns to the
Ready condition and waits for the next closure of the
Start/Increase push button. If Start/Increase is pressed
during postflow, the programs restart the weld se-
quence from the beginning without preflow timing.
Do not make connections to Remote 4 receptacle
RC2 at this time.
12.
13.
Energize welding power source.
If using the Semi-Automatic 5 mode, connect Remote
Pendant to Remote 4 receptacle RC2 at this time.
6.
The Stop push button is not functional in this mode.
However, the existence of the arc is monitored by the
control unit. If the arc is manually broken, the program
goes directly to postflow.
14.
Be sure the desired program is active before executing
a program. The active program is indicated in the appli-
cable repeating display (see Section 5-1F). To select a
different program, press Parameter Select while the re-
peating displays are shown. This increases the
program number.
D. Operation Procedures For Semi-Automatic 3
Mode
1.
When the unit is in the Ready condition (see Section
5-1F), press and hold the Start/Increase push button to
begin the weld sequence. After arc initiation at initial
current, the control unit maintains the programmed ini-
tial current value.
15.
16.
Begin welding, observing the operation procedures for
the applicable Semi-Automatic mode (see Sections
6-2B through 6-2F).
In all Semi-Automatic modes, the voltage and amper-
age meters display the weld voltage and amperage
while welding. The weld sequence displays are shown
on the digital display, with time values changing to re-
flect events being carried out.
2.
3.
Release the Start/Increase to signal the end of initial
time and the beginning of initial slope. Following initial
slope, the control unit maintains the programmed weld
current.
Press and hold Start/Increase to signal the end of Weld
Time and the beginning of final slope. Following final
slope, the control unit maintains the arc at the final cur-
rent level.
B. Operation Procedures For Semi-Automatic 1
Mode
1.
When the unit is in the Ready condition (see Section
5-1F), momentarily press Start/Increase to begin the
weld sequence.
4.
5.
Release Start/Increase to indicate the end of final cur-
rent and the beginning of postflow.
2.
During the Weld Time portion of the program, the Start/
Increase or Decrease push buttons may be pressed
and held to modify the weld current level within the de-
fined amperage adjustment limits (see Section 2-4).
The programmed values will not be affected.
After postflow is timed out, the control unit returns to the
Ready condition and waits for the next maintained clo-
sure of the Start/Increase push button. If Start/Increase
is pressed and held during postflow, the program re-
starts the weld sequence from the beginning without
preflow timing.
3.
4.
Before the weld sequence reaches Weld Time, the
Stop push button may be pressed to end the program
prematurely and send the weld sequence to postflow.
6.
The Stop push button is not functional in this mode.
However, the existence of the arc is monitored by the
control unit. If the arc is manually broken, the program
goes directly to postflow.
The Stop push button must be pressed during Weld
Time to signal the end of weld/peak current. When Stop
is pressed, the weld sequence enters final slope. Once
Weld Time is terminated, the Stop push button has no
affect on program operation.
E. Operation Procedures For Semi-Automatic 4
Mode
5.
After postflow is timed out, the control unit returns to the
Ready condition and waits for the next closure of the
Start/Increase push button. If Start/Increase is pressed
1.
When the unit is in the Ready condition (see Section
5-1F), momentarily press Start/Increase to begin the
weld sequence. After arc initiation at initial current, the
OM-842 Page 35
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control unit maintains the programmed initial current
value.
g. If the weld current output is decreased to the pro-
grammed final current, the program enters final
current and goes to postflow.
Program execution at this point varies according to
whether pulsing is enabled or disabled. Go to Step 2 if
pulsing is enabled, and Step 3 if pulsing is disabled.
h. If weld current never exceeds the programmed fi-
nal current, the weld current must be manually
decreased to zero, at which time the program be-
gins postflow.
2.
When pulsing is enabled:
a. Press and hold Start/Increase to increase the weld
current output. The peak current output increases
at a rate determined by the programmed value of
initial current level, initial slope time, and peak cur-
rent level. The background current output
increases at a rate determined by the programmed
value of initial current level, initial slope time, and
background current level.
4.
5.
After postflow is timed out, the control unit returns to the
Ready condition and waits for the next closure of the
Start/Increase push button. If Start/Increase is pressed
during postflow, the program restarts the weld se-
quence from the beginning without preflow timing.
The Stop push button is not functional in this mode.
However, the existence of the arc is monitored by the
control unit. If the arc is manually broken, the program
goes directly to postflow.
b. When Start/Increase is released, the peak and
background current levels that exist are main-
tained.
F. Operation Procedures For Semi-Automatic 5
Mode
c. The programmed peak and background current
levels define the maximum limit that the Start/In-
crease push button can command.
1.
When the unit is in the Ready condition (see Section
5-1F), momentarily press Start/Increase to begin pro-
gram execution. The control unit initiates the arc and
executes the programmed sequence to the pro-
grammed weld level. Press Start/Increase to indicate
the end of weld and the beginning of final slope. Once
final slope begins, the Start/Increase push button no
longer has any affect on program execution.
d. Press and hold the Decrease push button to de-
crease the weld current output. The peak current
output decreases at a rate determined by the pro-
grammed value of peak current, final slope time,
and final current level. The background current
output decreases at a rate determined by the pro-
grammed value of background current, final slope
time, and final current level.
2.
3.
After postflow is timed out, the control unit returns to the
Ready condition and waits for the next closure of the
Start/Increase push button. If Start/Increase is pressed
during postflow, the program restarts the weld se-
quence from the beginning without preflow timing.
e. When Decrease is released, the peak and back-
ground current levels that exist when the push
button is released are maintained.
f. Increasing and decreasing the pulsed weld current
output can go on indefinitely.
The Stop push button is not functional in this mode.
However, the existence of the arc is monitored by the
control unit. If the arc is manually broken, the program
goes directly to postflow.
g. If the weld current output is decreased to the value
programmed for final current, the program enters fi-
nal current and go to postflow.
6-3. Gas Tungsten Arc Welding (GTAW) In
The Manual Mode
h. If weld current never exceeds the programmed val-
ue for final current, the weld current must be
manually decreased to zero, at which time the pro-
gram begins postflow.
3.
When pulsing is disabled:
a. Press and hold the Start/Increase to increase the
weld current output. The output increases at a rate
determined by the programmed value of initial cur-
rent level, initial slope time, and weld current level.
1.
Be sure welding power source and related equipment
are installed as instructed in their respective Owner’s
Manuals.
2.
3.
Connect a suitable Contactor/Amperage remote con-
trol to the Remote 14 receptacle.
b. When Start/Increase is released, the weld current
level that exists when the push button is released is
maintained.
Be sure desired weld program (or programs) has been
entered.
c. The programmed weld current defines the maxi-
mum limit the Start/Increase push button can
command.
4.
5.
Place Mode Selector switch in Manual GTAW position.
Select and prepare tungsten electrode according to
d. Press and hold the Decrease push button to de-
crease the weld current output. The output
decreases at a rate determined by the pro-
grammed value of weld current, final slope time,
and final current level.
welding power source Owner’s Manual.
6.
7.
Insert electrode into torch.
Wear dry insulating gloves and clothing.
Connect work clamp to clean, bare metal at workpiece.
Turn on shielding gas supply at source.
8.
e. When Decrease is released, the weld current level
that exists when the push button is released is
maintained.
9.
10.
Wear welding helmet with proper filter lens according to
ANSI Z49.1.
f. Increasing and decreasing the weld current output
can go on indefinitely.
11.
Energize welding power source.
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12.
13.
Enter the Ready condition (see Section 5-1F). The op-
erator now has control of the welding power source
contactor via the remote contactor control connected
to the Remote 14 receptacle.
5.
6.
7.
8.
9.
Wear dry insulating gloves and clothing.
Connect work clamp to clean, bare metal at workpiece.
Select proper electrode.
Insert electrode into electrode holder.
Start welding as follows:
Wear welding helmet with proper filter lens according to
ANSI Z49.1.
a. Be sure the desired program is active before ex-
ecuting a program. The active program is indicated
in the applicable repeating display (see Section
5-1F). To select a different program, press Param-
eter Select while the repeating displays are shown.
This increases the program number.
10.
11.
12.
Energize welding power source.
Enter the Ready condition (see Section 5-1F).
Begin welding, observing the following:
a. Be sure the desired program is active before ex-
ecuting a program. The active program is indicated
in the applicable repeating display (see Section
5-1F). To select a different program, press Param-
eter Select while the repeating displays are shown.
This increases the program number.
b. Use the remote contactor control to energize the
welding power source contactor. This initiates
preflow.
c. If high frequency is enabled, a high-frequency arc
initiation at the defined start current level can be
performed after preflow.
b. A closure of the remote contactor control contacts
turns on the welding power source contactor. The
control unit waits for an arc to be initiated with the
stick electrode.
If high frequency is disabled, a touch or scratch
start at the defined initial current level can be per-
formed after preflow.
c. If Remote is enabled in the program (see Section
5-5), the remote control can be used to increase
the weld current up to the programmed maximum
weld level. The remote amperage control can de-
crease the weld current down to the minimum
current level the welding power source can pro-
vide.
14.
15.
While welding, the voltage and amperage meters dis-
play the weld voltage and amperage. The weld
sequence displays show on the digital display, with
time values changing to reflect events being carried
out.
Weld output can be varied with the remote amperage
control. If pulsing is programmed On, the remote am-
perage control can increase the weld/peak and
background current levels up to the programmed maxi-
mum values. The remote amperage control can
decrease the weld/peak and background current lev-
els down to the defined initial current level.
d. If Remote is disabled in the program, the control
unit sets the weld output to the programmed weld
level value.
e. Opening the remote contacts turns off the welding
power source contactor.
f. While welding, the voltage and amperage meters
display the weld voltage and amperage.
If pulsing is programmed Off, the remote amperage
control can increase the weld current up to the pro-
grammed maximum weld level. The remote amperage
control can decrease the weld current down to the de-
fined initial current level.
6-5. Executing Linked Programs
1.
Follow the Sequence Of Operation steps for the appli-
cable mode (Automatic, Semi-Automatic 1, or
Semi-Automatic 5) until the Ready condition is entered.
16.
17.
To stop welding, use the remote contactor control to
deenergize the welding power source contactor. Post-
flow will be carried out.
2.
When the repeating displays are shown, press Param-
eter Select until the program number increases beyond
4. The Link mode will be active.
After postflow is timed out, the control unit returns to the
Ready condition. The operator must use the remote
contactor control to energize the welding power source
contactor to start welding again. If the welding power
source contactor is energized during postflow, the pro-
gram restarts the weld sequence from the beginning
without preflow timing.
3.
4.
Be sure the Link position to be executed first is the first
one in the Link Position displays.
Press Start/Increase on the Remote Pendant to begin
linked program execution.
6-6. Executing Combined Programs
6-4. Shielded Metal Arc Welding (SMAW)
1.
Follow the Sequence Of Operation steps for the appli-
cable mode (Automatic, Semi-Automatic 1, or
Semi-Automatic 5) until the Ready condition is entered.
2.
When the repeating displays are shown, press Param-
eter Select until the program number increases beyond
4. The Link mode will be active.
1.
Be sure welding power source and related equipment
are installed as instructed in their respective Owner’s
Manuals.
3.
4.
Press Parameter Select again to enter the Combine
mode.
2.
3.
4.
Be sure desired weld program (or programs) has been
entered.
Press Start/Increase on the Remote Pendant to begin
combined program execution.
Connect a suitable Contactor/Amperage remote con-
trol to the Remote 14 receptacle.
6-7. Shutting Down
Place Mode Selector switch in SMAW position.
1.
Stop welding.
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2.
3.
Turn off welding power source.
A L L O W
T O
C O O L
Turn off shielding gas supply at the source, if applica-
ble.
B E F O R E
C O N T I N U I N G
The ammeter and voltmeter displays flash until one of the fol-
lowing events takes place:
1.
The thermostat resets (indicating the unit has cooled
down).
6-8. Overheating Protection
2.
3.
The operator turns the unit Off and then On again.
The operator moves the Program/Run/Reset keyed
switch to the Reset position, then to either Run or Pro-
gram, as applicable.
If the unit overheats, the weld sequence goes to postflow and
the contactor is deenergized. The user relay contacts stay in
the state they were in before postflow was entered and remain
that way until postflow ends. The following repeating displays
are shown:
If the operator carries out items 2 or 3 above, the program pa-
rameters can be viewed or modified, but the unit output
contactor cannot be energized. If the operator tries to energize
the contactor, the unit goes to postflow and repeats the dis-
plays shown above.
P O W E R
S O U R C E
If the unit overheats, wait until the unit cools down before start-
ing to weld.
T H E R M A L
O V E R L O A D
SECTION 7 – DIAGNOSTICS
Postflow relay
7-1. Introduction
Wire Feed Time Delay relay
A. General
Pulse Signal relay
Remote Pendant
The diagnostics program allows the following to be tested:
13.
14.
15.
1.
2.
Internal RAM memory
Front panel programming push buttons
Run and Program positions of the keyed switch
Output selector switch
Mode selector switch
Purge push button
Current detection circuitry
Input contactor
3.
The RAM test and the programming push button tests are car-
ried out each time the diagnostics program is started. The
remaining tests can be performed in sequence, or the Right/In-
crease or Left/Decrease push buttons can be used to access a
desired test. Refer to the subsections in this section for infor-
mation on each test.
4.
5.
6.
7.
Analog output circuitry
Output contactor
8.
B. Running The Diagnostics Program
9.
Background relay
To carry out the diagnostics program, proceed as follows:
10.
11.
12.
Gas solenoid relay
1.
2.
3.
Follow the directions in Section 2-4 for choosing the
diagnostics program on DIP switch SW1.
Arc starter relay
User relays, which include the following:
Initial Time relay
Place Program/Run/Reset keyed switch in Run
position.
Energize the unit.
Initial Slope relay
Weld Time relay
C. Stopping The Diagnostics Program
Final Slope relay
To stop the diagnostics program, follow the directions in Sec-
tion 2-4 for choosing program execution on DIP switch SW1.
Final Time relay
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B. Programming Push Button Tests
7-2. Diagnostics Program
1.
After the RAM test is passed, the front panel program-
ming push button tests are carried out. The display
shows:
When the diagnostics program starts, the following series of in-
formational displays is shown:
P L E A S E
P U S H
B U T T O N
* S Y N C R O W A V E
3 5 1 *
R I G H T / I N C
D I A G N O S T I C P R O G R A M
2.
When this display appears, the control unit waits nine
seconds for the Right/Increase push button to be
pressed. If this is done in time and the push button is
working properly, the display shows:
T H E
F O L L O W I N G
P R O G R A M W I L L
C H E C K
R I G H T / I N C
W O R K I N G
B U T T O N
I S
Y O U R
U N I T
T H A T
T O
I T
V E R I F Y
P R O P E R L Y
I S
If the Right/Increase push button tests okay, go to Step
4.
3.
If the Right/Increase push button is not pressed in time,
or if the push button is not working correctly, the follow-
ing displays appear:
F U N C T I O N I N G
P R O P E R L Y
E R R O R
R I G H T
B U T T O N
A. RAM Test
I S N O T
W O R K I N G
1.
After the four informational displays are shown, the in-
ternal RAM (random access memory) of the
microprocessor control is tested to make sure each
memory location is working properly. If the RAM tests
okay, the display shows:
P L E A S E
C O R R E C T
E R R O R
B E F O R E
C O N T I N U I N G
R A M
I S W O R K I N G
P R O P E R L Y
W I T H
T H E
D I A G N O S T I C
P R O G R A M
T E S T
If the RAM tests okay, go to Step 3.
2.
If the RAM does not test okay, the following displays
appear:
If the Right/Increase push button is not working correct-
ly, replace the push button.
4.
When the Right/Increase push button tests okay, the
diagnostics program tests the Left/Decrease push but-
ton. The display shows:
E R R O R ! ! !
N O T W O R K I N G
R A M
I S
P R O P E R L Y
P L E A S E
P U S H
P L E A S E
B E F O R E
R E P L A C E
R A M
L E F T / D E C
B U T T O N
C O N T I N U I N G
5.
When this display appears, the control unit waits nine
seconds for the Left/Decrease push button to be
pressed. If this is done in time and the push button is
working correctly, the display shows:
W I T H
T H E
D I A G N O S T I C
P R O G R A M
T E S T
L E F T / D E C
W O R K I N G
B U T T O N
I S
P R O P E R L Y
If the RAM does not test okay, contact the nearest Fac-
tory Authorized Service Station/Service Distributor.
3.
When the RAM tests okay, the diagnostics program
proceeds to the next test.
If the Left/Decrease push button tests okay, go to Step
7.
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6.
If the Left/Decrease push button is not pressed in time,
or if the push button is not working correctly, the follow-
ing displays appear:
If the Parameter Select push button is not working cor-
rectly, replace the push button.
10.
When the Parameter Select push button tests okay, the
repeating test displays appear.
E R R O R
L E F T
B U T T O N
C. Repeating Test Displays
I S N O T
W O R K I N G
1.
When the RAM memory and programming push but-
tons test okay, the repeating test displays appear as
follows:
P L E A S E
C O R R E C T
E R R O R
* S Y N C R O W A V E
3 5 1 *
B E F O R E
C O N T I N U I N G
D I A G N O S T I C
P R O G R A M
W I T H
T H E
D I A G N O S T I C
P R O G R A M
U S E
R I G H T / I N C
O R
T E S T
L E F T / D E C
T O
S E L E C T
If the Left/Decrease push button is not working correct-
ly, replace the push button.
T H E
T O
F U N C T I O N
T E S T
7.
When the Left/Decrease push button tests okay, the
diagnostics program tests the Parameter Select push
button. The display shows:
P A R A M E T E R
B E G I N / E N D
S E L E C T
T O
P L E A S E
P U S H
S E L E C T
T H E T E S T
P A R A M E T E R
2.
The remaining diagnostic tests can be accessed from
8.
When this display appears, the control unit waits nine
seconds for the Parameter Select push button to be
pressed. If this is done in time and the push button is
working correctly, the display shows:
these displays. This is done by pressing either the
Right/Increase or Left/Decrease push buttons. The
tests are presented in the following subsections in the
order they would follow if the Right/Increase push but-
ton was repeatedly pressed. The Left/Decrease push
button would access the tests in the opposite order.
P A R A M E T E R
I S W O R K I N G
S E L E C T
When a test is accessed and the Parameter Select
push button is not pressed to begin the test, the repeat-
ing test displays are shown.
P R O P E R L Y
If the Parameter Select push button tests okay, go to
Step 10.
D. Program/Run/Reset Keyed Switch Tests
This procedure tests the Run and Program positions of the
Program/Run/Reset keyed switch.
9.
If the Parameter Select push button is not pressed in
time, or if the push button is not working correctly, the
following displays appear:
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase once. The display
shows:
E R R O R
P A R A M E T E R
K E Y E D
S W I T C H
S E L E C T
N O T
W O R K I N G
T E S T
2.
3.
Press Parameter Select to begin the test. The display
shows:
P L E A S E
C O R R E C T
E R R O R
B E F O R E
C O N T I N U I N G
P L E A S E
R U N
P U T
K E Y
I N
P O S I T I O N
W I T H
T H E
D I A G N O S T I C
P R O G R A M
T E S T
When this display appears, the control unit waits three
seconds for the keyed switch to be placed in the Run
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position. If this is done in time and the position is work-
ing correctly, the display shows:
A C / D C
S W I T C H
T E S T
R U N
P O S I T I O N
P R O P E R L Y
I S W O R K I N G
2.
3.
Press Parameter Select to begin the test.
Place Output Selector switch in ac position. If switch is
working properly, the display shows:
If the Run position tests okay, go to Step 5.
4.
If the keyed switch is not placed in the Run position in
time, or if the position is not working correctly, the dis-
play shows:
A C / D C
A C
S W I T C H
I S
I N
P O S I T I O N
E R R O R ! !
I S N O T
R U N
P O S I T I O N
4.
Place Output Selector switch in either of the dc posi-
tions. If Process Selector switch is working properly,
the display shows:
W O R K I N G
A C / D C
S W I T C H
I S
I N
If the Run position is not working correctly, replace the
keyed switch.
D C – E P
O R D C – E N
5.
When the Run position tests okay, press Parameter
Select. The display shows:
5.
6.
Place the switch in the ac position. The display indicat-
ing ac position should again be shown.
P L E A S E
P U T
K E Y
I N
If the display changes to match the position of the Pro-
cess Selector switch, the switch is operating correctly.
If the display does not change to match the position of
the switch, replace the Output Selector switch.
P R O G R A M
P O S I T I O N
6.
When this display appears, the control unit waits three
seconds for the keyed switch to be placed in the Pro-
gram position. If this is done in time and the position is
working correctly, the display shows:
When the Output Selector switch tests okay, press Pa-
rameter Select to exit the test. Use the Right/Increase
or Left/Decrease push button to access another test, or
stop the diagnostics program.
F. Mode Selector Switch Test
P R O G R A M
I S W O R K I N G
P O S I T I O N
P R O P E R L Y
This procedure tests the positions of the Mode Selector switch.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
If the Program position tests okay, go to Step 8.
7.
If the keyed switch is not placed in the Program position
in time, or if the position is not working correctly, the dis-
play shows:
M O D E
S W I T C H
T E S T
E R R O R ! !
I S N O T
P R O G R A M
W O R K I N G
2.
Press Parameter Select to begin the test. The display
shows:
P L E A S E
T U R N
K N O B
T O
If the Program position is not working correctly, replace
the keyed switch.
S M A W – M A N U A L
P O S I T I O N
8.
When the Program position tests okay, press Parame-
ter Select to exit the keyed switch tests. Use the
Right/Increase or Left/Decrease push button to access
another test, or stop the diagnostics program.
3.
When this display appears, the control unit waits three
seconds for the Mode Selector switch to be placed in
the SMAW position. If this is done in time and the posi-
tion is working correctly, the display shows:
E. Output Selector Switch Test
S M A W – M A N U A L
P O S I T I O N
This procedure tests the positions of the Output Selector
switch.
W O R K I N G P R O P E R L Y
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
If the SMAW position tests okay, go to Step 5.
OM-842 Page 41
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4.
If the Mode Selector switch is not placed in the SMAW
position in time, or if the position is not working correct-
ly, the display shows:
E R R O R ! !
I S N O T
S E M I – A U T O
W O R K I N G
E R R O R ! !
I S N O T
S M A W – M A N U A L
If the Semi-Automatic position is not working correctly,
replace the Mode Selector switch.
W O R K I N G
11.
When the Semi-Automatic position tests okay, press
Parameter Select. The display shows:
If the SMAW position is not working correctly, replace
the Mode Selector switch.
P L E A S E
T U R N
K N O B
T O
5.
When the SMAW position tests okay, press Parameter
Select. The display shows:
G T A W – A U T O
P O S I T I O N
P L E A S E
T U R N
K N O B
T O
12.
When this display appears, the control unit waits three
seconds for the Mode Selector switch to be placed in
the Automatic position. If this is done in time and the po-
sition is working correctly, the display shows:
G T A W – M A N U A L
P O S I T I O N
6.
When this display appears, the control unit waits three
seconds for the Mode Selector switch to be placed in
the Manual GTAW position. If this is done in time and
the position is working correctly, the display shows:
G T A W – A U T O
I S W O R K I N G
P O S I T I O N
P R O P E R L Y
G T A W – M A N U A L
P O S I T I O N
If the Automatic position tests okay, go to Step 14.
W O R K I N G P R O P E R L Y
13.
If the Mode Selector switch is not placed in the Auto-
matic position in time, or if the position is not working
correctly, the display shows:
If the Manual GTAW position tests okay, go to Step 8.
7.
If the Mode Selector switch is not placed in the Manual
GTAW position in time, or if the position is not working
correctly, the display shows:
E R R O R ! !
I S N O T
G T A W
A U T O
W O R K I N G
E R R O R !
I S N O T
G T A W M A N U A L
W O R K I N G
If the Automatic position is not working correctly, re-
place the Mode Selector switch.
14.
When the Automatic position tests okay, press Param-
eter Select to exit the Mode Selector switch test (the
Reset position is not tested). Use the Right/Increase or
Left/Decrease push button to access another test, or
stop the diagnostics program (see Section 2-4).
If the Manual GTAW position is not working correctly,
replace the Mode Selector switch.
8.
When the Manual GTAW position tests okay, press Pa-
rameter Select. The display shows:
G. Purge Push Button Test
This procedure tests the purge push button.
P L E A S E
G T A W
T U R N
K N O B
T O
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
S E M I – A U T O
P U R G E
B U T T O N
9.
When this display appears, the control unit waits three
seconds for the Mode Selector switch to be placed in
the Semi-Automatic position. If this is done in time and
the position is working correctly, the display shows:
T E S T
2.
3.
Press Parameter Select to begin the test. The display
shows:
S E M I – A U T O
I S W O R K I N G
P O S I T I O N
P R O P E R L Y
P L E A S E
P U R G E
P U S H
B U T T O N
If the Semi-Automatic position tests okay, go to Step 11.
10.
If the Mode Selector switch is not placed in the
Semi-Automatic position in time, or if the position is not
working correctly, the display shows:
When this display appears, the control unit waits three
seconds for the Purge push button to be pressed. If this
OM-842 Page 42
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is done in time and the push button is working correctly,
the display shows:
6.
Use the VOM to check for a dc voltage within the speci-
fied range across pins C and D of the Remote 14
receptacle. If an acceptable voltage is present, go to
Step 8.
B U T T O N
I S
7.
8.
If the correct dc input reference voltage is not found,
contact the nearest Factory Authorized Service
Station/Service Distributor.
W O R K I N G P R O P E R L Y
When the analog output circuitry tests okay, press Pa-
rameter Select to exit the test. Use the Right/Increase
or Left/Decrease push button to access another test, or
stop the diagnostics program.
If the Purge push button tests okay, go to Step 5.
4.
If the Purge push button is not pressed in time, or if the
push button is not working correctly, the display shows:
B U T T O N
I S
N O T
I. Output Contactor Test
W O R K I N G
P R O P E R L Y
WARNING
If the Purge push button is not working correctly, re-
place the push button.
ELECTRIC SHOCK can kill; OPEN
CIRCUIT
VOLTAGE
ACROSS
OUTPUT TERMINALS is present
5.
When the Purge push button tests okay, press Param-
eter Select to exit the Purge push button test. Use the
Right/Increase or Left/Decrease push button to access
another test, or stop the diagnostics program (see Sec-
tion 2-4).
during testing.
• Do not touch live electrical parts.
• Disconnect any cables from weld output
terminals before performing test.
Have only qualified persons familiar with and
followingstandard safety practices perform this test.
H. +10 Volt DC Reference Test
This procedure tests the analog output circuitry of the micro-
processor control.
This procedure tests the output contactor.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
+ 1 0 V
R E F E R E N C E
T E S T
O U T P U T
C O N T A C T O R
T E S T
2.
Press Parameter Select to begin the test. The display
shows:
2.
Press Parameter Select to begin the test. This ener-
gizes the output contactor. The display shows:
C H E C K
R M T 1 4
+ 1 0 V
C ( + )
T O
D
F O R
+ / – . 0 5 V
C H E C K
5 3 T O
V O L T
6 7
M E T E R
V O L T S
F O R
D C
3.
Use a suitable VOM (volt-ohmmeter) to check for a dc
voltage within the specified range across pins C and D
of the Remote 14 receptacle. If an acceptable voltage
is present, press Parameter Select and go to Step 5.
3.
The Voltage meter on the control unit should indicate a
voltage within the specified range.
4.
5.
If the correct dc input reference voltage is not found,
contact the nearest Factory Authorized Service
Station/Service Distributor.
If an acceptable voltage is not indicated, contact the
nearest Factory Authorized Service Station/Service
Distributor.
The display shows:
4.
When the output contactor tests okay, press Parameter
Select to deenergize the output contactor and exit the
test. Use the Right/Increase or Left/Decrease push
button to access another test, or stop the diagnostics
program.
C H E C K
F O R
R M T 1 4
+ 5 V
C ( + )
T O
D
+ / – . 0 5 V
OM-842 Page 43
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J. Background Relay Test
L. Arc Starter Relay Test
This procedure tests the internal dc background current
source.
This procedure tests the arc starter relay. Indirectly, the Arc
Starter Board PC8 is also tested.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
B A C K G R O U N D
A R C
S T A R T E R
T E S T
R E L A Y
T E S T
R E L A Y
2.
Press Parameter Select to begin the test. This ener-
gizes the background relay. The display shows:
2.
Press Parameter Select to energize the arc starter
relay. The display shows:
C H E C K
4 2 T O
V O L T
5 4
M E T E R
V O L T S
F O R
D C
A R C
I S
S T A R T E R
R E L A Y
E N E R G I Z E D
3.
The Voltage meter on the control unit should indicate a
voltage within the specified range.
3.
4.
If a crackling sound can be heard inside the welding
power source, the relay is working correctly. In this
case, go to Step 4.
If an acceptable voltage is not indicated, contact the
nearest Factory Authorized Service Station/Service
Distributor.
If a crackling sound is not heard inside the welding
power source, contact the nearest Factory Authorized
Service Station/Service Distributor.
4.
When the background relay tests okay, press Parame-
ter Select to deenergize the relay and exit the test. Use
the Right/Increase or Left/Decrease push button to ac-
cess another test, or stop the diagnostics program.
When the relay tests okay, press Parameter Select
again to deenergize the relay. The program automati-
cally returns to the repeating test displays. Use the
Right/Increase or Left/Decrease push button to access
another test, or stop the diagnostics program.
K. Gas Solenoid Relay Test
This procedure tests the gas solenoid relay. Indirectly, the gas
solenoid is also tested.
M. User Relays
This procedure tests the user relays (see Section 2-3). Since
the procedure is the same for each of the user relays, one ex-
ample is presented that applies to all the user relays.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows the test display for the desired relay.
G A S
S O L E N O I D
T E S T
R E L A Y
For example, if the initial time relay is being tested, the
display would show:
2.
Press Parameter Select to energize the gas solenoid
relay. The display shows:
I N I T I A L
R E L A Y
T I M E
T E S T
G A S
I S
S O L E N O I D
R E L A Y
E N E R G I Z E D
2.
Press Parameter Select to begin the test. The display
shows:
3.
4.
If gas flows, the gas solenoid relay and gas solenoid
are working correctly. In this case, go to Step 4.
I N I T I A L
T I M E
R E L A Y
If gas does not flow, contact the nearest Factory Autho-
rized Service Station/Service Distributor.
I S E N E R G I Z E D
When the gas solenoid relay tests okay, press Parame-
ter Select again to deenergize the relay. The program
automatically returns to the repeating test displays.
Use the Right/Increase or Left/Decrease push button
to access another test, or stop the diagnostics pro-
gram.
After a short pause, the relay energizes.
3.
Use a suitable VOM (volt-ohmmeter) to check the re-
sistance across the relay terminals as shown in
Figure 7-1.
OM-842 Page 44
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0 Ohms
OL
N. Remote Pendant Test
This procedure tests the operation of the push buttons on the
Remote Pendant.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
R E M O T E
P E N D A N T
T E S T
A
B
C
2.
Press Parameter Select to begin the test. The display
shows:
P U S H
O N
S T A R T / I N C
R E M O T E
Figure 7-1. Testing Energized User Relay
4.
If the relay is working correctly, the VOM reads the re-
sistances shown. In this case, go to Step 5.
3.
When this display appears, the control unit waits three
seconds for the Start/Increase push button to be
pressed. If this is done in time and the push button is
working correctly, the display shows:
If the VOM does not read the resistances shown while
the relay is energized, contact the nearest Factory Au-
thorized Service Station/Service Distributor.
B U T T O N
I S
5.
6.
Press Parameter Select again to deenergize the relay.
The program automatically returns to the repeating test
displays.
W O R K I N G P R O P E R L Y
Use the VOM to check the resistance across the relay
terminals as shown in Figure 7-2.
If the Start/Increase push button tests okay, go to Step
5.
4.
If the Start/Increase push button is not pressed in time,
or if the push button is not working correctly, the display
shows:
OL
0 Ohms
B U T T O N
I S
N O T
W O R K I N G
P R O P E R L Y
If the Start/Increase push button is not working correct-
ly, replace the push button.
5.
When the Start/Increase push button tests okay, press
Parameter Select. The display shows:
A
B
C
P U S H
D E C R E A S E
O N R E M O T E
B U T T O N
Figure 7-2. Testing Deenergized User Relay
6.
When this display appears, the control unit waits three
seconds for the Decrease push button to be pressed. If
this done in time and the push button is working cor-
rectly, the display shows:
7.
8.
If the relay is working correctly, the VOM reads the re-
sistances shown. In this case, go to Step 8.
If the VOM does not read the resistances shown while
the relay is deenergized, contact the nearest Factory
Authorized Service Station/Service Distributor.
B U T T O N
I S
W O R K I N G P R O P E R L Y
When the applicable user relay tests okay, use the
Right/Increase or Left/Decrease push button to access
another test, or stop the diagnostics program.
If the Decrease push button tests okay, go to Step 8.
OM-842 Page 45
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7.
If the Decrease push button is not pressed in time, or if
the Decrease push button is not working correctly, the
display shows:
2.
Press Parameter Select. The display scrolls through
the following two displays:
P U T
O N
S H O R T
C I R C U I T
S T U D S
B U T T O N
I S
N O T
O U T P U T
W O R K I N G
P R O P E R L Y
R I G H T / I N C
C O N T I N U E T H I S
T O
T E S T
If the Decrease push button is not working correctly, re-
place the push button.
8.
When the Decrease push button tests okay, press Pa-
rameter Select. The display shows:
3.
4.
Connect a suitable cable across the output terminals.
The microprocessor control sends a reference current
through the cable when Right/Increase is pressed.
P U S H
O N
S T O P
B U T T O N
Press Right/Increase. If the current detect circuitry is
working correctly, the display shows:
R E M O T E
C U R R E N T
W O R K I N G
D E T E C T
I S
9.
When this display appears, the control unit waits three
seconds for the Stop push button to be pressed. If this
is done in time and the push button is working correctly,
the display shows:
P R O P E R L Y
If the current detect circuitry tests okay, go to Step 6.
5.
If the current detect circuitry is not working correctly, the
display shows:
B U T T O N
I S
W O R K I N G P R O P E R L Y
C U R R E N T
D E T E C T
I S
N O T W O R K I N G
P R O P E R L Y
If the Stop push button tests okay, go to Step 11.
10.
If the Stop push button is not pressed in time, or if the
push button is not working correctly, the display shows:
If the current detect circuitry is not working correctly,
contact the nearest Factory Authorized Service
Station/Service Distributor.
B U T T O N
I S
N O T
6.
When the current detect circuitry tests okay, press Pa-
rameter Select to exit the test. Use the Right/Increase
or Left/Decrease push button to access another test, or
stop the diagnostics program.
W O R K I N G
P R O P E R L Y
If the Stop push button is not working correctly, replace
the push button.
P. Input Contactor Test
This procedure tests the circuitry that detects an input contac-
tor closure.
11.
When the Stop push button tests okay, press Parame-
ter Select to exit the Remote Pendant tests. Use the
Right/Increase or Left/Decrease push button to access
another test, or stop the diagnostics program.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
O. Current Detect Test
I N P U T
C O N T A C T O R
T E S T
This procedure tests the operation of the circuitry that detects
output current flow.
1.
When the repeating test displays are shown (see Sec-
tion 7-2C), press Right/Increase or Left/Decrease until
the display shows:
2.
Press Parameter Select to begin the test. The display
shows:
C U R R E N T
T E S T
D E T E C T
P R O V I D E
O N R C 3
A
C L O S U R E
P I N S T O
A
B
OM-842 Page 46
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3.
When this display appears, the control unit waits three
seconds for the specified contact closure. If this is done
in time and the solid state contactor is working correct-
ly, the display shows:
I N P U T
N O T
C O N T A C T O R
D E T E C T E D
I S
I N P U T
I S
C O N T A C T O R
D E T E C T E D
If the input contactor circuitry is not working correctly,
contact the nearest Factory Authorized Service
Station/Service Distributor.
If the input contactor detection circuitry tests okay, go to
Step 5.
5.
When input contactor closure tests okay, press Param-
eter Select to exit the test. Use the Right/Increase or
Left/Decrease push button to access another test, or
stop the diagnostics program.
4.
If the input contactor closure is not carried out in time, or
if the related circuitry is not working correctly, the dis-
play shows:
OM-842 Page 47
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SECTION 8 – ELECTRICAL DIAGRAMS
SA-132 263
Figure 8-1. Circuit Diagram For Remote Pendant
OM-842 Page 48
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SC-161 093-B
Figure 8-2. Wiring Diagram For MPC Module
OM-842 Page 49
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Figure 8-3. Circuit Diagram For Welding Power Source And MPC
OM-842 Page 50
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SC-182 947-B
OM-842 Page 51
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SECTION 9 – PARTS LIST
. Hardware is common and
not available unless listed.
ST-162 780
Figure 9-1. Main Assembly
OM-842 Page 52
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 9-1. Main Assembly
Quantity
. . . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 158 955 . . COVER, front electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 078 034 . . FASTENER, screw sltd hd .736 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 010 855 . . RETAINER, screw No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . 4
. . . 6 . . PLG13,31 . . 155 511 . . CABLE, ribbon 10posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . PC8 . . . . . 157 741 . . CIRCUIT CARD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . PC9 . . . . . 156 046 . . DISPLAY, LED 2 x 20 alphanumeric fluorescent . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG33 . . . . 156 045 . . CONNECTOR, rect 14skt plug Amp 1-640440-4 . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . PLG19,29 . . 142 138 . . CABLE, ribbon 14posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . PC7 . . . . . 151 518 . . CIRCUIT CARD, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG30 . . . . 115 094 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 157 792 . . STRAP, grounding panel front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 107 551 . . STRAIN RELIEF, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 010 494 . . BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . PC3 . . . . . 157 737 . . CIRCUIT CARD, relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . PLG4,9 . . . 142 142 . . CABLE, ribbon 14posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . PC2 . . . . . 157 802 . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . PLG7,12 . . . 142 141 . . CABLE, ribbon 40posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . LF1 . . . . . 084 171 . . FILTER, line pwr 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 144 713 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 134 201 . . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . . . . . . . . . 20
. . . 21 . . . . . . . . . . . . . . . 098 691 . . STAND-OFF, 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . PC6 . . . . . 180 158 . . CIRCUIT CARD, interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG24 . . . . 153 501 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG26 . . . . 148 439 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG28 . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG32 . . . . 153 501 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . PLG20,25 . . 155 427 . . CABLE, ribbon 24posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . PC5 . . . . . 151 648 . . CIRCUIT CARD, microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG21 . . . . 152 249 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG22 . . . . 148 439 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . PLG14,23 . . 153 599 . . CABLE, ribbon 40posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . PC1 . . . . . 182 090 . . CIRCUIT CARD, control main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG15 . . . . 148 439 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG16 . . . . 150 317 . . CONNECTOR, rect 4 pin/skt plug Amp 172167-1 . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . CONNECTOR, rect skt 22-18ga Amp 170362-3 . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . . 158 960 . . STRIP, mtg door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 073 756 . . STAND-OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 29 . . . . . . S1 . . . . . 125 945 . . SWITCH, key 3posn .750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 115 360 . . KNOB, arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 115 359 . . CAP, peaked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 089 186 . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . RC3 . . . . . 073 687 . . CONNECTOR, circ 4skt rcpt Amphenol MS-3102A-14S-2S . . . . . . . . . . 1
. . . 34 . . . C16-19 . . . 157 856 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 35 . . . . . . . . . . . . . . . 603 107 . . HOSE, nprn slit bk .156 ID x .343 OD (order by ft) . . . . . . . . . . . . . . . . . . 1ft
. . . 36 . . . . . . . . . . . . . . . 158 959 . . DOOR, access terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . 3T,4T . . . . 038 833 . . BLOCK, term 20A 13P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . . 126 908 . . BEZEL/FILTER, blue filter/nonglare 4 in . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 071 230 . . BEZEL/FILTER, blk bezel/red filter 2.000 viewing . . . . . . . . . . . . . . . . . . . 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-842 Page 53
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
132 064
Figure 9-2. Pendant
. . . 1 . . . . . . . . . . . . . . . 079 725 . . GUARD, switch al knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 134 429 . . CASE SECTION, front/end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . S1 . . . . . 079 724 . . SWITCH, PB MC SPDT 6A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . S2,3 . . . . . 021 105 . . SWITCH, PB Licon 76-2351 SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 148 348 . . CASE SECTION, back/sides/end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 134 900 . . STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 604 571 . . CABLE, port No. 18 4/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ft
. . . 9 . . . . . . . . . . . . . . . 039 828 . . CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6 . . . . 1
. . . 10 . . . . PLG50 . . . . 053 075 . . CONNECTOR, circ 4 pin plug Amphenol MS-3106A-14S-2P . . . . . . . . . 1
4
. Hardware is common and
not available unless listed.
3
2
5
1
6
4
7
10
9
8
ST-146 840-A
Figure 9-2. Pendant
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-842 Page 54
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Notes
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Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
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:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
Service
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 date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
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
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.
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.
1. 5 Years Parts – 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
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.
2. 3 Years — Parts and Labor
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
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.
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
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.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
Grids
Maxstar 140
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
Spot Welders
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
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.
*
Field Options
(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.)
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
miller_warr 7/00
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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
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
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
Contact the Delivering Carrier for:
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
2000 Miller Electric Mfg. Co. 6/00
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