OM-220 812B
March 2005
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
CST 250 VRD
International
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Stick (SMAW) Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-4. TIG (GTAW) Volt-Ampere Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-6. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-7. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-8. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-10. Selecting 220 Volts AC Single/Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-11. Selecting 400 - 440 Volts AC Three Phase Input Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-2. Process Select Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-3. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-5. Amp Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-7. Fan-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-8. Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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Marks a special safety message.
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1-2. Arc Welding Hazards
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
Safety Standards.
D
D
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If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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D
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
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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
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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
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Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
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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
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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
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
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.
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Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
OM-220 812 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D
Wear 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.
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D
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Wear approved safety glasses with side shields under your
helmet.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
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
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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.
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D
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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.
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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.
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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.
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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.
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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.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
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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.
OM-220 812 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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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.
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Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
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Have only qualified persons familiar with
electronic equipment perform this installation.
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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
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
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Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
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Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
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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.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
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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
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
D
1-4. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-220 812 Page 3
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1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
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-220 812 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi-
lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les me-
sures à prendre pour éviter tout danger.
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Identifie un message de sécurité particulier.
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a
s
é
c
u
r
i
t
é
.
2-2. Dangers relatifs au soudage à l’arc
Y
Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
Lire et respecter toutes ces normes.
D
N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne doi-
vent être confiés qu’à des personnes qualifiées.
Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
d’entrée et les circuits internes de l’appareil sont également sous tension.
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. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D
Arrêter les convertisseurs, débrancher le courant électrique et dé-
charger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
D
D
Ne jamais toucher aux pièces électriques sous tension.
Porter des gants et des vêtements de protection secs et exempts de
trous.
S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-
tifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humi-
des, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de souda-
ge l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-
vir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-
lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor-
mes de sécurité).
Installer et mettre à la terre correctement l’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.
Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est en-
dommagé − tout câble dénudé peut causer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D
D
Se tenir à distance des fumées et ne pas les inhaler.
À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D
D
Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
Lire les fiches techniques de santé−sécurité (FTSS) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D
D
D
Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dû-
ment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respira-
ble.
D
D
D
D
Ne pas souder 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 irri-
tants.
D
D
Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien venti-
lé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dé-
gager des fumées toxiques lorsqu’on les soude.
D
D
Ne pas s’enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
D
OM-220 812 Page 5
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LES RAYONS DE L’ARC peuvent cau-
ser des brûlures oculaires et cuta-
nées.
LES ACCUMULATIONS DE GAZ peu-
vent causer des blessures ou même
la mort.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) suscep-
tibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
D
Veiller toujours à bien ventiler les espaces confinés ou porter un respira-
teur à adduction d’air agréé.
D
Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour re-
garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
LES PIÈCES CHAUDES peuvent cau-
ser des brûlures graves.
D
D
Porter des lunettes de sécurité à écrans latéraux sous le masque.
Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
D
D
Ne pas toucher les pièces chaudes à main nue.
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D
LE SOUDAGE peut causer un incen-
die ou une explosion.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimu-
lateurs cardiaques.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauf-
fement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
D
Ils doivent consulter leur médecin avant de s’appro-
cher d’un lieu où on exécute des opérations de sou-
dage à l’arc, de gougeage ou de soudage par points.
D
D
D
Se protéger et protéger les tiers de la projection d’étincelles et de mé-
tal chaud.
Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
Placer 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 agréées.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
D
D
D
Des étincelles et des matières en fusion peuvent facilement passer
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
même par des fissures et des ouvertures de petites dimensions.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
mité.
Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’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 que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’in-
cendie.
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 au raz du tube−contact.
Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
Les BOUTEILLES endommagées
peuvent exploser.
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
D
manipuler avec précaution.
D
D
D
Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D
D
D
Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
cuits électriques.
D
Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
D
D
Ne jamais poser une torche de soudage sur une bouteille de gaz.
Ne jamais mettre une électrode de soudage en contact avec une bou-
teille de gaz.
D
D
Ne jamais souder une bouteille contenant du gaz sous pression − elle
LES PARTICULES PROJETÉES peu-
vent blesser les yeux.
risquerait d’exploser.
N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-
tion ou de branchement de la bouteille
Lire et suivre les instructions concernant les bouteilles de gaz compri-
mé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
D
Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalli-
D
D
ques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-220 812 Page 6
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2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLO-
SION
LES ORGANES MOBILES peuvent
causer des blessures.
D
Ne pas placer l’appareil sur une surface inflam-
mable, ni au−dessus ou à proximité d’elle.
D
Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D
Maintenir fermés et bien fixés 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 dimensionnée et protégée avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H. F.) risque de causer des
interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radio-
navigation et de communication, les services de
sécurité et les ordinateurs.
D
N’utiliser que l’anneau de levage pour lever l’ap-
pareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
Utiliser un engin de capacité adéquate pour lever
l’appareil.
D
D
D
D
Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
Si la Federal Communications Commission signale des interféren-
ces, arrêter immédiatement l’appareil.
D
Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté op-
posé de l’appareil.
D
D
Faire régulièrement contrôler et entretenir l’installation.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
Maintenir soigneusement fermés les panneaux et les portes des sour-
ces de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interféren-
ces éventuelles.
D
Prévoir une période de refroidissement ; respec-
ter le cycle opératoire nominal.
D
Réduire le courant ou le cycle opératoire avant de
reprendrele soudage.
LE SOUDAGE À L’ARC peut causer
des interférences.
D
Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
D
L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir-
cuits imprimés.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit compati-
ble au point de vue électromagnétique.
Pour réduire la possibilité d’interférence, maintenir les câbles de sou-
dage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D
Mettre un bracelet antistatique AVANT de mani-
puler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
D
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que le poste de soudage soit posé et mis à la terre confor-
mément au présent manuel.
En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires tel-
les que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES PIÈCES MOBILES peuvent cau-
ser des blessures.
D
D
Se tenir à l’écart des pièces mobiles.
Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
LES FILS DE SOUDAGE peuvent cau-
ser des blessures.
D
D
Porteurs de stimulateur cardiaque, restez à dis-
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.
D
Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en en-
gageant le fil de soudage.
D
OM-220 812 Page 7
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2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone: (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
tional.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
NationalElectrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé-
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca-
nadian Standards Association, Standards Sales, 178 boulevard
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnéti-
ques basse fréquence sur l’organisme
Afin de réduire les champs électromagnétiques en milieu de travail, res-
pecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
En parcourant les câbles de soudage, le courant crée des champs élec-
tromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumula-
tion de preuves n’a pas démontré que l’exposition aux champs
magnétiqueset aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la re-
cherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiquespendant le soudage ou le coupage.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignesrelatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-
mandé de respecter les consignes ci-dessus.
OM-220 812 Page 8
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SECTION 3 − INSTALLATION
3-1. Specifications
Welding
Mode
Input
Power
Rated
Output
Welding
Maximum
Amperes Input At Rated Load
Net
Weight
Amperage Open-Circuit Output, 50/60 Hz
KVA
KW
Dimensions
Range
Voltage
220
400
440
250 A @
30 VDC,
50 % Duty
Cycle
32.1
18.2
16.4
12.3
8.7
3-Phase
1-Phase
5-250 A
30 VDC
200 A @
28 VDC,
100 %
H: 13-1/2 in
(343 mm)
W: 7-1/2 in
(191 mm)
D: 18 in (457
mm)
24.2
42.6
33.6
14.4
n/a
12.6
n/a
9.9
10.0
7.4
6.5
6.6
5.7
Duty Cycle
Stick
(SMAW)
40 lb
(18.2 kg)
200 A @
28 VDC,
50 % Duty
Cycle
5-200 A
30 VDC
150 A @
26 VDC,
100 %
n/a
n/a
Duty Cycle
3-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops, and
cooling fan runs. Wait fifteen
minutes for unit to cool. Reduce
amperage or duty cycle before
welding.
Y
Exceeding duty cycle can
damage unit and void
warranty.
206 173
200 A @ 50% Duty Cycle For Single Phase Operation
250 A @ 50% Duty Cycle For 3 Phase Operation
5 Minutes Welding
5 Minutes Resting
5 Minutes Welding
5 Minutes Resting
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
OM-220 812 Page 9
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3-3. Stick (SMAW) Volt-Ampere Curves
Volt-amperecurves show minimum
and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
shown.
XX10 STICK VA CURVES
90
80
70
60
50
40
30
20
10
30A SOFT
50
30A STIFF 250ASOFT
200 250 300
250ASTIFF
350 400
0
0
100
150
DC AMPS
XX18 STICK VA CURVES
90
80
70
60
50
40
30
20
10
0
30A SOFT
30A STIFF
150
250ASOFT
250ASTIFF
300
0
50
100
200
250
350
DC AMPS
OM-220 812 Page 10
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3-4. TIG (GTAW) Volt-Ampere Curve
Volt-amperecurves show minimum
and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
shown.
LIFT ARC TIG (GTAW)
35
30
25
20
15
10
5
0
0
50
100
150
200
250
300
DC AMPS
OM-220 812 Page 11
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3-5. Selecting A Location
1
Line Disconnect Device
Locate unit near correct input
power supply.
Dimensions And Weight
40 lb (18.2 kg) - with power cord
Y
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in
(457 mm)
13-1/2 in
(343 mm)
7-1/2 in
(191 mm)
Location And Airflow
1
18 in
(460 mm)
18 in
(460 mm)
803 080
OM-220 812 Page 12
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3-6. Weld Output Terminals And Selecting Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding
150 ft
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60% 60 − 100%
Weld Output
Terminals
Welding
Amperes***
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
250
300
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
+
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
−
1/0 (60)
3/0 (95) 4/0 (120)
Output Receptacles
* This chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
2
( ) = mm for metric use
***Select weld cable size for pulsing application at peak amperage value.
S-0007-E−803 080
OM-220 812 Page 13
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3-7. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections
1
Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4
2
Negative (−) Weld Output
Terminal
5
6
Connect TIG torch to negative weld
output terminal.
3
4
Gas Cylinder
3
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5
6
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas hose to
regulator/flowmeter.
1
7
Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.
2
7
Tools Needed:
11/16 in, 1-1/8 in, (21 mm)
Ref. 802 888 / Ref. 803 080
OM-220 812 Page 14
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3-8. Stick DCEP (Direct Current Electrode Positive) Connections
1
Negative (−) Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2
Positive (+) Weld Output
Terminal
Connect electrode holder to
positive weld output terminal.
2
1
Ref. 802 888 / Ref. 803 080
3-9. Electrical Service Guide
Y CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding
power source requires a CONTINUOUS supply of 50/60 Hz power at + 10% of rated input voltage. Do
not use a generator with automatic idle device (that idles engine when no load is sensed) to supply
input power to this welding power source.
Actual input voltage cannot exceed 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
NOTE
50/60 Hz Single-Phase,
50% Duty Cycle
50/60 Hz Three-Phase,
50% Duty Cycle
Input Voltage
220
45
220
400
18
440
Input Amperes At Rated Output
Max Recommended Standard Fuse Rating In Amperes
32
16
1
2
50
40
50
10
20
25
14
20
25
14
Time-Delay
Normal Operating 3
70
Min Input Conductor Size In AWG/Kcmil
8
129 (39)
8
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
132 (40) 174 (53) 210 (64)
10 14 14
Reference: 2002 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y
Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
OM-220 812 Page 15
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3-10. Selecting 220 Volts AC Single/Three Phase Input Voltage
Y
Turn Off welding power
source, and disconnect
input
power
before
proceeding.
Check input voltage available at
site.
1
Voltage Selection View
Window
The input voltage that the power
source is linked for appears in the
Voltage Selection View Window.
Check voltage selected in unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
1
To change relinking board position,
remove top cover and left side
panel.
2
3
Relinking Board
Terminal Screws
Loosen terminal screws.
4
Relinking Board (Connection
For 220 VAC Single/Three
Phase Input Power)
Slide relinking board off connected
terminals, move relinking board to
correct input voltage terminals, and
secure relinking board.
2
. Be sure to tighten all four screws
securing relinking board in place.
3
4
Tools Needed:
5/16 in
803 079 / 803 077
OM-220 812 Page 16
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3-11. Selecting 400 - 440 Volts AC Three Phase Input Voltage
Y
Turn Off welding power
source, and disconnect
input
power
before
proceeding.
Check input voltage available at
site.
1
Voltage Selection View
Window
The input voltage that the power
source is linked for appears in the
Voltage Selection View Window.
Check voltage selected in unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
1
To change relinking board position,
remove top cover and left side
panel.
2
3
4
Relinking Board
Unused Terminal
Terminal Screws
Loosen terminal screws.
5
Relinking Board (Connection
For 400 - 440 VAC Input
Power)
Slide relinking board off connected
terminals, move relinking board to
correct input voltage terminals, and
secure relinking board.
2
3
.
B
e
s
u
r
e
t
o
t
i
g
h
t
e
n
a
l
l
f
o
u
r
s
c
r
e
w
s
.
T
h
r
e
e
5
screws securing relinking board in place.
4
3
Tools Needed:
5/16 in
803 079 / 803 078
OM-220 812 Page 17
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3-12. Connecting Input Power
Y
Y
Disconnect and lockout/tag-
out input power before
connecting input conduc-
tors from unit.
Have only qualified persons
make this installation.
See rating label on unit and check
input voltage available at site.
1
Input And Grounding
Conductors
3
1
2
Line Disconnect Device
For three-phase
operation:
Y
Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
2
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
2
For single-phase
operation:
Y
Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
L1
L2
L1
L2
L3
3
Black And White Input
Conductor
Green Or
4
5
6
Red Input Conductor
Insulation Sleeving
Electrical Tape
Green Or
Green/Yellow
Green/Yellow
Y
Always connect grounding
conductor first
Insulate and isolate red conductor
as shown.
= GND/PE
1
3
1
4
Green or
Green/Yellow
5
6
1
input_2 3/96 - 803 080
OM-220 812 Page 18
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SECTION 4 − OPERATION
4-1. Controls
2
5
3
4
1
CST 250 VRD
6
NOTE:Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
2
Output Indicator Light
4
Amp Adjust Control
5 High Temperature Shutdown Light
When unit is first energized this indicator
light flashes several times and then
illuminatescontinuously. When unit is shut
down, the indicator light flashes several
times and the cooling fan will run briefly,
then both will turn off completely.
1
Power Switch
When unit is first energized this indicator
light illuminates for approximately 1 second
to provide visual confirmation that the light
Use switch to turn unit and indicator light
On/Off.
3
Process Select Control
6
Remote 14 Receptacle
220 685-A / 803 080
OM-220 812 Page 19
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4-2. Process Select Control
1
Process Select Control
Rotate knob to select desired
process.
1
Lift-Arc
t
TIG
-
Normal
open-circuit voltage is not present
between the electrode and
workpiece. A solid-state contactor
does not energize until after the
electrode touches the workpiece,
preventingoverheating, sticking, or
contaminating the electrode (see
Stick E XX18 Soft - This setting
provides a lower dig/arc force
setting
for
smooth
weld
perfromance.A stable weld puddle
with little arc “snap” gives excellent
weld bead appearance with
minimalspatter. Make connections
Stick E XX18 Stiff - This setting
provides a higher dig/arc force that
gives a slightly more fluid weld
puddle, more arc “snap”, and
reduces the potential for electrode
sticking at shorter arc lengths.
Make connections according to
Stick E XX10 Soft - This setting
provides lower dig/arc force for
open root vertical up joints or joints
that do not require additional
current for fit up inconsistencies.
Make connections according to
RECOMMENDED PROCESS
SELECTIONS VS ELECTRODE TYPE
Stick E XX10 Stiff - This setting
provides a higher dig/arc force for
open root vertical down joints
where additional current is needed
to compensate for tight joint fit up
without the need to increase overall
welding current. Make connections
ELECTRODE SUGGESTED PROCESS
TYPE
SETTING
EXXX1
EXXX2
EXX10
EXX10
EXXX3
EXXX4
EXX18
EXX18
EXX18
EXX18
EXX18
EXX18
EXX18
EXXX5
EXXX6
EXXX7
EXXX8
STAINLESS
OM-220 812 Page 20
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4-3. Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
1
2
Normal open-circuit voltage is not
present before electrode touches
workpiece; only a low sensing voltage
is present between electrode and
workpiece. This allows electrode to
touch workpiece without overheating,
sticking, or getting contaminated.
3
4-4. Lift-Arc™ Start Procedure
Lift-Arc Start
With Lift-Arct selected, start arc
as follows:
1
2
TIG Electrode
Workpiece
Turn gas on. Touch tungsten
electrodeto workpiece at weld start
point.
Hold
electrode
to
workpiece for 1-2 seconds, and
slowly lift electrode. Arc is formed
when electrode is lifted.
Lift-Arc Start Method
1
2
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
1 − 2
“Touch”
Seconds
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.
Do NOT Strike Like A Match!
OM-220 812 Page 21
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4-5. Amp Adjust Control
1
AMP ADJUST (Amperage
Control)
1
Rotate knob clockwise to increase
amperage (5-250 amps).
4-6. Remote 14 Receptacle Information
This unit automatically senses when a remote control is connected to the remote 14 receptacle. After connecting a
remote control, the unit will automatically adjust output control to a primary/secondary configuration. In this
configuration, the AMP ADJUST control on the unit becomes the primary and sets the maximum amperage output of
the unit. The remote control becomes the secondary and provides an amperage range adjustment of 0 to 100% based
on the AMP ADJUST control setting.
Socket*
Socket Information
A
J
K
I
B
C
A
B
15 volts dc (not functional).
L
N
H
M
D
G
15 VOLTS DC
F
E
Contact closure to A completes 15 volts dc
contactor control circuit (not functional).
C
D
E
Output to remote control; 0 to +10 volts dc.
Remote control circuit common.
REMOTE
OUTPUT
CONTROL
0 to +10 volts dc input command signal from
remote control.
K
Chassis common.
GND
803 080
*The remaining sockets are not used.
4-7. Fan-On-Demand
This unit is equipped with Fan-On-Demand. The fan operates only when necessary to cool internal components. At
power down, the fan will operate for a short period of time while the output indicator light is flashing.
4-8. Rack Mounting
This unit is capable of being rack mounted [see rack Owner’s Manual, OM-2238 (208 107)].
OM-220 812 Page 22
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SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y
Disconnect power before maintaining.
.
M
a
i
n
t
a
i
n
m
o
r
e
o
f
t
e
n
d
u
r
i
n
g
s
e
v
e
r
e
c
o
n
d
i
t
i
o
n
s
.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals.
Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Y
Do not remove case when
blowing out inside of unit
Blow out inside. During
heavy service clean
monthly.
5-2. Blowing Out Inside Of Unit
Y
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
803 080
OM-220 812 Page 23
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5-3. Troubleshooting
1
2
Output LED (Blue)
High Temperature LED
(Yellow)
1
2
803 080
Trouble
Possible Causes
Remedy
No weld output; unit completely
inoperative.
Line disconnect switch open.
Place line disconnect switch in On position (see Section
3-12).
Blown line fuse(s).
Check and replace line fuse(s), if necessary, or reset
Improper input power connections.
Check for proper input power connections (see Section
3-12).
Line voltage too high or too low.
Unit not linked correctly.
Unit needs to be reset.
Line voltage must be within 10%.
No weld output.
Blue LED flashes continuously, yellow
LED off.
Check line voltage and link unit accordingly.
Cycle power switch off and back on again. If problem is not
corrected, contact nearest Factory Authorized Service
Agent.
No weld output.
Voltage in excess of 100 V from an Check and correct any external voltage sources.
Blue LED flashes 4 times repeatedly, external source across output studs.
yellow LED off.
No weld output.
Short circuit across output studs.
Check and correct any short circuit conditions.
Blue LED flashes 5 times repeatedly,
yellow LED off.
Single phase rating exceeded (output Reduce output to 200 amperes or less.
foldback due to excessive input current).
Low weld output.
Blue LED flashes 2 times repeatedly,
yellow LED off.
High output VA coupled with a low 230 Check line voltage and weld settings.
voltage line (output foldback due to
excessive input current).
No weld output.
Blue LED flashes 3 times repeatedly,
yellow LED off.
Remote trigger left on.
Turn off remote trigger, wait approximately 5 seconds, and
restart operation.
No weld output.
Internal component failure.
Contact nearest Factory Authorized Service Agent.
Blue LED flashes 6 times repeatedly,
yellow LED off.
No weld output.
Unit overheated.
Thermistor failure.
Allow unit to cool.
Blue LED off, yellow LED on.
No weld output.
Have Factory Authorized Service Agent check thermistor.
Blue LED off, yellow LED flashes
continuously.
Fan not operating.
Blocked fan blade.
Fan failure.
Check and remove anything blocking fan blade movement.
Have Factory Authorized Service Agent check fan motor.
OM-220 812 Page 24
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Trouble
Possible Causes
Weld cable too small or defective.
Dirty or loose connections.
Improper size tungsten.
Remedy
Erratic or improper weld output.
Shield weld zone from drafts.
Wandering arc
Worn or defective tungsten.
Shielding gas flow too high.
Shielding gas blown away from weld
zone.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Inadequatepostflow time.
Allow adequate postflow time to shield tungsten while it
cools, after welding stops.
Loose or leaking gas fittings.
Water in torch.
Refer to torch manual.
OM-220 812 Page 25
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SECTION 7 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.
NOTE
7-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode
DC − Argon − Electrode
AC − Argon − Using
High Frequency
AC − Argon − Balanced
Wave Using High Freq.
Negative/Straight Polarity Positive/Reverse Polarity
2% Thorium Alloyed
Tungsten (Red Band)
.010”
.020”
.040”
1/16”
3/32”
1/8”
Up to 25
15-40
*
Up to 20
15-35
Up to 15
5-20
*
25-85
*
20-80
20-60
50-160
10-20
15-30
25-40
40-55
55-80
80-125
50-150
130-250
225-360
300-450
400-500
600-800
60-120
100-180
160-250
200-320
290-390
340-525
135-235
250-400
400-500
500-750
750-1000
5/32”
3/16”
1/4”
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
7-2. Safety Information About Tungsten
Y
Grinding the tungsten elec-
trode produces dust and fly-
ing sparks which can cause
injury and start fires. Use lo-
cal exhaust (forced ventila-
tion) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodescontains low-lev-
el radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1
2
1
2
Tungsten Electrode With
Balled End
Pointed Tungsten Electrode
Ref. S-0161
OM-220 812 Page 27
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7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1
2
Tungsten Electrode
Tapered End
1
2
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
Stable Arc
Flat
1
2
Diameter of this flat determines
amperagecapacity.
3
Grinding Wheel
Grinding wheel should be dedi-
cated to grinding tungsten only.
3
4
Straight Ground
4
Ideal Tungsten Preparation − Stable Arc
1
2
3
Arc Wander
Point
1
2
3
Grinding Wheel
Grinding wheel should be dedi-
cated to grinding tungsten only.
4
Radial Ground
4
Wrong Tungsten Preparation − Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-220 812 Page 28
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Notes
OM-220 812 Page 29
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . 205758 . . PANEL,FRONT W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 205780 . . PANEL,REAR W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 212809 . . MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 206090 . . HEAT SINK ASSEMBLY,OUTPUT DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 206039 . . BASE ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 206093 . . BRACKET,MTG CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 206038 . . HEAT SINK ASSEMBLY,INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 206164 . . COVER,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 206165 . . PANEL,SIDE LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 206166 . . PANEL,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 207437 . . CABLE,POWER 6 FT 10GA 4C BLK/RED/WHT/GRNYEL . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 206108 . . HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 206289 . . LINK,CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . PLG3 . 206247 . . PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . PLG4 . 206254 . . PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 196231 . . XFMR,CURRENT SENSING 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 206269 . . INSULATOR,SIDE LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 206270 . . INSULATOR,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . PLG5 . 206276 . . CABLE,LEM W/PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . C1,C2 . 203912 . . CAPACITOR,ELCTLT 2400 UF 500 VDC CAN 2.5 DIA . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . 205908 . . CLAMP,CAPACITOR 2.500 DIA HORIZONTAL MTG NYLON . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 189777 . . RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 134327 . . LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE FE . . . . . 1
. . . . . . . . . . . . . . . . 185835 . . LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 182826 . . LABEL,WARNING ELECTRIC SHOCK POWER CORD . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 180994 . . LABEL,WARNING MATCH INPUT POWER TO VOLTAGE SHOWN . . . . . . . 1
. . . 23 . . . PC2 . . 222447 . . KIT,CIRCUIT CARD ASSY INTERCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . PC1 . . 205772 . . CIRCUIT CARD ASSY,POWER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . PC5 . . 205776 . . CIRCUIT CARD ASSY,RELINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 176879 . . SCREW,M 5− .8X 12 HEX HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 27 . . . . . . . . . . . 207113 . . WASHER,CONE .205IDX0.394ODX.015T STL . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . 186329 . . SCREW,M10−1.5X 25 HEX HD−PLN 8.8 PLD . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-220 812 Page 31
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4
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15
6
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3
7
17
11
21
16
10
803 158
Figure 8-2. Panel, Front w/Components
Item
No.
Diagram
marking
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . 194242 . . PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 205759 . . PANEL,FRONT UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 195647 . . PANEL,FRONT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . S1 . . . . . . 207165 . . SWITCH,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 174991 . . KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 174992 . . KNOB,POINTER .840 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . 1
. . . 7 . . RC14 . . . . . 207144 . . RECEPTACLE W/LEADS&PLUG,(14 PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 193115 . . STAND−OFF SUPPORT,PC CARD .156 DIA/.375 LG NYLON . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . 178548 . . TERMINAL,CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . 202553 . . RECEPTACLE,TWIST LOCK DINSE(FEMALE)POWER . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . 185712 . . INSULATOR,BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . 185713 . . INSULATOR,BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . 185714 . . WASHER,TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN . . . . . . 2
. . . 14 . . . . . . . . . . . . . . 185717 . . NUT,M20−1.5 1.06HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . 185718 . . O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . 186228 . . O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . 207253 . . BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 220685 . . NAMEPLATE,MILLER CST 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . PC4 . . . . . . 205764 . . CIRCUIT CARD ASSY,OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . PC3 . . . . . . 220810 . . CIRCUIT CARD ASSY,PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 170391 . . CONNECTOR, CIRC MS PROTECTIVE CAP . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 178355 . . NUT, 375−32 .54HEX .25H NYL FLANGE .62D2 . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . 209554 . . SCREW, KA35X 8 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-220 812 Page 32
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803 161-B
4
Figure 8-3. Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Panel, Rear w/Components
. . . 1 . . . . . . . . . . 194242 . . PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206052 . . PANEL,REAR UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 206053 . . PANEL,REAR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 210128 . . BRACKET,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 145217 . . SCREW,K40X 12 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . 207253 . . BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . 201155 . . BUSHING,STRAIN RELIEF .450/.709 ID X1.068 MTG HOLE . . . . . . . . . . . . . 1
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-220 812 Page 33
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8
14
7
3
8
12
11
16
6
10
9
8
1
15
5
2
4
803 163-B
Figure 8-4. Magnetics Subassembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-4. Magnetics Subassembly
. . . 1 . . . . . . . . . . 206063 . . PANEL,PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . T1 . . 212812 . . XFMR,HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . FM . . 196887 . . FAN,MUFFIN 24VDC 3000 RPM 130 CFM 4.125 MTG HOLES . . . . . . . . . . . 1
. . . 4 . . . . Z1 . . 206064 . . INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . CR1 . . 206258 . . RELAY,ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . . . . . . . . . . . 1
. . . 6 . . . . R3 . . 206281 . . RESISTOR,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . C3 . . 196143 . . CAPACITOR,POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 057357 . . BUSHING,SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . . 3
. . . 9 . . . . . . . . . . 109056 . . CORE,FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . . . . . 1
. . . 10 . . . . L3 . . 206273 . . COIL,INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 196514 . . GASKET,INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 196512 . . BRACKET,INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 198634 . . BRACKET,FRONT HEATSINK MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 083147 . . GROMMET,SCR NO 8/10 PANEL HOLE .312 SQ .500 HIGH . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 136343 . . SCREW,K50X 20 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . 170647 . . BUSHING,SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . . 1
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-220 812 Page 34
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6
2
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3
8
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5
803 159-C
Figure 8-5. Heat Sink Assembly, Output Diode
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . 205916 . . HEAT SINK,DIODE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . D1,D2 . 223422 . . KIT,DIODE ULTRA−FAST RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . SR1 . . 201530 . . KIT,DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . HD1 . . 191941 . . TRANSDUCER,CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . R2,C6 . 196510 . . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . R1,C5 . 207384 . . RESISTOR/CAPACITOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . RT1 . . 199798 . . THERMISTOR,NTC 30K OHM @ 25 DEG C 18IN LEAD . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . 049611 . . TUBING,COP .540 OD X .123 WALL X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 207932 . . INSULATOR,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 108942 . . SCREW,250−20X1.25 HEXWHD.61D GR5 PLD . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 602 062 . . SCREW,004−40X .37 PAN HD−PHL STL PLD CONE SEMS . . . . . . . . . . . . . 5
. . . 12 . . . . . . . . . . 070427 . . SCREW,008−32X .50 SOC HD−HEX GR8 PLD . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 13 . . . . . . . . . . 602200 . . WASHER,LOCK .168IDX0.293ODX.040T STL PLD SPLIT #8 . . . . . . . . . . . . 7
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-220 812 Page 35
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803 160
Figure 8-6. Base Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . 206089 . . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 019663 . . MOUNT,NPRN 15/16ODX3/8REC 3/16X3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . C7,C8 . 186543 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . 133528 . . RIVET,AL .125 DIA X .188−.250 GRIP BLK BLIND DOME . . . . . . . . . . . . . . . 4
. . . 5 . . . . . . . . . . 195666 . . SCREW,010−32X .62 HEXWHD.40D STL PLD SLFFMG TAP−RW . . . . . . . . 2
. . . 6 . . . . . . . . . . 601862 . . NUT, 010−32 .38HEX .13H STL PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . 602203 . . WASHER,LOCK .193IDX0.334ODX.047T STL PLD SPLIT #10 . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . 602238 . . WASHER,FLAT .203IDX0.500ODX.048T STL PLD ANSI#10 . . . . . . . . . . . . . 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-220 812 Page 36
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Figure 8-7. Heat Sink Assembly, Input
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . 205915 . . HEAT SINK,IGBT/INPUT RECTIFIER MODULE . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 206091 . . BRACKET,HEATSINK REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . TE1 . . 206328 . . BLOCK,TERM 70 AMP 3 POLE SCREW TERM 4−14 WIRE . . . . . . . . . . . . . 1
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-220 812 Page 37
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Notes
Download from Www.Somanuals.com. All Manuals Search And Download.
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
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.
Canvas Covers
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the 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
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
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.
*
*
*
*
Water Coolant Systems (Integrated)
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches
miller_warr 1/05
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2005 Miller Electric Mfg. Co. 1/05
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