OM-228 723A 2006−02

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Arc Welding Power Source

CST 280

File: Stick (SMAW)

Visit our website at

www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

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

Mil_Thank 4/05
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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-Arc 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 - 230 Volts AC Single/Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-11. Selecting 460 - 575 Volts AC Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-12. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-13. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-2. Process Select Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-3. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-4. Lift-Arc Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-5. Amperage 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 7 − SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
 Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

This group of symbols means Warning! Watch Out! possible

 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
 Means “Note”; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to  Turn off all equipment when not in use.
call attention to and identify possible hazards. When you see  Do not use worn, damaged, undersized, or poorly spliced cables.
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only  Do not drape cables over your body.
a summary of the more complete safety information found in  If earth grounding of the workpiece is required, ground it directly
the Safety Standards listed in Section 1-5. Read and follow all with a separate cable.
Safety Standards.  Do not touch electrode if you are in contact with the work, ground,
 Only qualified persons should install, operate, maintain, and or another electrode from a different machine.
repair this unit.  Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
 During operation, keep everybody, especially children, away.
present.
 Use only well-maintained equipment. Repair or replace damaged
ELECTRIC SHOCK can kill. parts at once. Maintain unit according to manual.
 Wear a safety harness if working above floor level.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is  Keep all panels and covers securely in place.
electrically live whenever the output is on. The input  Clamp work cable with good metal-to-metal contact to workpiece
power circuit and machine internal circuits are also or worktable as near the weld as practical.
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the  Insulate work clamp when not connected to workpiece to prevent
welding wire are electrically live. Incorrectly installed or improperly contact with any metal object.
grounded equipment is a hazard.  Do not connect more than one electrode or work cable to any
 Do not touch live electrical parts. single weld output terminal.
 Wear dry, hole-free insulating gloves and body protection.
SIGNIFICANT DC VOLTAGE exists in inverter-type
 Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
welding power sources after removal of input
or ground. power.
 Do not use AC output in damp areas, if movement is confined, or if  Turn Off inverter, disconnect input power, and discharge input
there is a danger of falling. capacitors according to instructions in Maintenance Section
 Use AC output ONLY if required for the welding process. before touching any parts.
 If AC output is required, use remote output control if present on FUMES AND GASES can be hazardous.
unit.
 Additional safety precautions are required when any of the follow-
Welding produces fumes and gases. Breathing
ing electrically hazardous conditions are present: in damp these fumes and gases can be hazardous to your
locations or while wearing wet clothing; on metal structures such health.
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-  Keep your head out of the fumes. Do not breathe the fumes.
able or accidental contact with the workpiece or ground. For these  If inside, ventilate the area and/or use local forced ventilation at the
conditions, use the following equipment in order presented: 1) a arc to remove welding fumes and gases.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
 If ventilation is poor, wear an approved air-supplied respirator.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder  Read and understand the Material Safety Data Sheets (MSDSs)
is recommended. And, do not work alone! and the manufacturer’s instructions for metals, consumables,
 Disconnect input power or stop engine before installing or coatings, cleaners, and degreasers.
servicing this equipment. Lockout/tagout input power according to  Work in a confined space only if it is well ventilated, or while
OSHA 29 CFR 1910.147 (see Safety Standards). wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
 Properly install and ground this equipment according to its
lower the oxygen level causing injury or death. Be sure the breath-
Owner’s Manual and national, state, and local codes.
ing air is safe.
 Always verify the supply ground − check and be sure that input  Do not weld in locations near degreasing, cleaning, or spraying op-
power cord ground wire is properly connected to ground terminal in erations. The heat and rays of the arc can react with vapors to form
disconnect box or that cord plug is connected to a properly highly toxic and irritating gases.
grounded receptacle outlet.
 Do not weld on coated metals, such as galvanized, lead, or
 When making input connections, attach proper grounding conduc- cadmium plated steel, unless the coating is removed from the weld
tor first − double-check connections. area, the area is well ventilated, and while wearing an air-supplied
 Frequently inspect input power cord for damage or bare wiring − respirator. The coatings and any metals containing these elements
replace cord immediately if damaged − bare wiring can kill. can give off toxic fumes if welded.
OM-228 723 Page 1
 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense  Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays  Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
 Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
 Wear approved safety glasses with side shields under your
helmet.  Do not touch hot parts bare handed.
 Allow cooling period before working on gun or
 Use protective screens or barriers to protect others from flash,
torch.
glare and sparks; warn others not to watch the arc.
 To handle hot parts, use proper tools and/or
 Wear protective clothing made from durable, flame-resistant mate-
wear heavy, insulated welding gloves and
rial (leather, heavy cotton, or wool) and foot protection.
clothing to prevent burns.

WELDING can cause fire or explosion.

MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks  Pacemaker wearers keep away.
can fly off from the welding arc. The flying sparks, hot  Wearers should consult their doctor before
workpiece, and hot equipment can cause fires and going near arc welding, gouging, or spot
burns. Accidental contact of electrode to metal objects can cause welding operations.
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. NOISE can damage hearing.
 Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
 Protect yourself and others from flying sparks and hot metal. damage hearing.
 Be alert that welding sparks and hot materials from welding can  Wear approved ear protection if noise level is
easily go through small cracks and openings to adjacent areas. high.
 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. CYLINDERS can explode if damaged.
 Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see Shielding gas cylinders contain gas under high
Safety Standards). pressure. If damaged, a cylinder can explode. Since
 Connect work cable to the work as close to the welding area as gas cylinders are normally part of the welding
practical to prevent welding current from traveling long, possibly process, be sure to treat them carefully.
unknown paths and causing electric shock, sparks, and fire  Protect compressed gas cylinders from excessive heat, mechani-
hazards. cal shocks, physical damage, slag, open flames, sparks, and arcs.
 Do not use welder to thaw frozen pipes.  Install cylinders in an upright position by securing to a stationary
 Remove stick electrode from holder or cut off welding wire at support or cylinder rack to prevent falling or tipping.
contact tip when not in use.  Keep cylinders away from any welding or other electrical circuits.
 Wear oil-free protective garments such as leather gloves, heavy  Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap.
 Never allow a welding electrode to touch any cylinder.
 Remove any combustibles, such as a butane lighter or matches,
 Never weld on a pressurized cylinder − explosion will result.
from your person before doing any welding.
 Use only correct shielding gas cylinders, regulators, hoses, and fit-
 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
tings designed for the specific application; maintain them and
for hot work and have a fire watcher and extinguisher nearby.
associated parts in good condition.
 Turn face away from valve outlet when opening cylinder valve.
FLYING METAL can injure eyes.  Keep protective cap in place over valve except when cylinder is in
use or connected for use.
 Welding, chipping, wire brushing, and grinding  Use the right equipment, correct procedures, and sufficient num-
cause sparks and flying metal. As welds cool, ber of persons to lift and move cylinders.
they can throw off slag.
 Read and follow instructions on compressed gas cylinders,
 Wear approved safety glasses with side associated equipment, and Compressed Gas Association (CGA)
shields even under your welding helmet. publication P-1 listed in Safety Standards.

OM-228 723 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

 Do not install or place unit on, over, or near  Keep away from moving parts such as fans.
combustible surfaces.  Keep all doors, panels, covers, and guards
 Do not install unit near flammables. closed and securely in place.
 Do not overload building wiring − be sure power supply system is  Have only qualified persons remove doors,
properly sized, rated, and protected to handle this unit. panels, covers, or guards for maintenance as
necessary.
 Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
FALLING UNIT can cause injury.
 Use lifting eye to lift unit only, NOT running READ INSTRUCTIONS.
gear, gas cylinders, or any other accessories.
 Use equipment of adequate capacity to lift and  Read Owner’s Manual before using or servic-
support unit. ing unit.
 If using lift forks to move unit, be sure forks are  Use only genuine Miller/Hobart replacement
long enough to extend beyond opposite side of parts.
unit.

H.F. RADIATION can cause interference.

OVERUSE can cause OVERHEATING  High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
 Allow cooling period; follow rated duty cycle. communications equipment.
 Reduce current or reduce duty cycle before  Have only qualified persons familiar with
starting to weld again. electronic equipment perform this installation.
 Do not block or filter airflow to unit.  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
STATIC (ESD) can damage PC boards. equipment at once.
 Have the installation regularly checked and maintained.
 Put on grounded wrist strap BEFORE handling  Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
 Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

ARC WELDING can cause interference.

MOVING PARTS can cause injury.  Electromagnetic energy can interfere with
sensitive electronic equipment such as
 Keep away from moving parts. computers and computer-driven equipment
 Keep away from pinch points such as drive such as robots.
rolls.  Be sure all equipment in the welding area is
electromagnetically compatible.
 To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can cause injury.  Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
 Do not press gun trigger until instructed to do  Be sure this welding machine is installed and grounded
so. according to this manual.
 Do not point gun toward any part of the body,  If interference still occurs, the user must take extra measures
other people, or any metal when threading such as moving the welding machine, using shielded cables,
welding wire. using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

 Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause  Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
 Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of  Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
OM-228 723 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
www.global.ihs.com). ternational.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard ANSI Standard Z87.1, from American National Standards Institute, 11
AWS F4.1 from Global Engineering Documents (phone: West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
1-877-413-5184, website: www.global.ihs.com). website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269−9101 (phone: 617−770−3000, website: www.nfpa.org). P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway, OSHA, Occupational Safety and Health Standards for General Indus-
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
site: www.cganet.com). and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices−−phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale 312−353−2220,website: www.osha.gov).

1-6. EMF Information

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

OM-228 723 Page 4

 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som _3/05
 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

Symbole graphique d’avertissement ! Attention ! Cette pro-
cédure comporte des risques possibles ! Les dangers éven-
tuels sont représentés par les symboles graphiques joints.

 Indique un message de sécurité particulier Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
 Signifie NOTE ; n’est pas relatif à la sécurité. les dangers.

2-2. Dangers relatifs au soudage à l’arc

 Les symboles représentés ci-dessous sont utilisés dans ce manuel  Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
pour attirer l’attention et identifier les dangers possibles. En n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
présence de l’un de ces symboles, prendre garde et suivre les peut entraîner la mort.
instructions afférentes pour éviter tout risque. Les instructions en  L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
matière de sécurité indiquées ci-dessous ne constituent qu’un  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
sommaire des instructions de sécurité plus complètes fournies ou mal épissés.
dans les normes de sécurité énumérées dans la Section 2-5. Lire et  Ne pas enrouler les câbles autour du corps.
observer toutes les normes de sécurité.
 Si la pièce soudée doit être mise à la terre, le faire directement avec un
 Seul un personnel qualifié est autorisé à installer, faire fonction- câble distinct.
ner, entretenir et réparer cet appareil.  Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
 Pendant le fonctionnement, maintenir à distance toutes les per- ou une électrode provenant d’une autre machine.
sonnes, notamment les enfants de l’appareil.  Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
UNE DÉCHARGE ÉLECTRIQUE peut  N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
entraîner la mort. champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Le contact d’organes électriques sous tension peut  Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est  S’assurer que tous les panneaux et couvercles sont correctement en
sous tension lorsque le courant est délivré à la place.
sortie. Le circuit d’alimentation et les circuits internes de la machine  Fixer le câble de retour de façon à obtenir un bon contact métal-métal
sont également sous tension lorsque l’alimentation est sur Marche. avec la pièce à souder ou la table de travail, le plus près possible de la
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de soudure.
commande du rouleau et toutes les parties métalliques en contact  Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec le fil sont sous tension électrique. Un équipement installé ou mis avec tout objet métallique.
à la terre de manière incorrecte ou impropre constitue un danger.  Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
 Ne pas toucher aux pièces électriques sous tension.
 Porter des gants isolants et des vêtements de protection secs et sans
Il reste une TENSION DC NON NÉGLIGEABLE dans
trous. les sources de soudage onduleur quand on a coupé
 S’isoler de la pièce à couper et du sol en utilisant des housses ou des l’alimentation.
tapis assez grands afin d’éviter tout contact physique avec la pièce à  Arrêter les convertisseurs, débrancher le courant électrique et
couper ou le sol. décharger les condensateurs d’alimentation selon les instructions indi-
 Ne pas se servir de source électrique à courant électrique dans les zo- quées dans la partie Entretien avant de toucher les pièces.
nes humides, dans les endroits confinés ou là où on risque de tomber. LES FUMÉES ET LES GAZ peuvent
 Se servir d’une source électrique à courant électrique UNIQUEMENT si être dangereux.
le procédé de soudage le demande.
 Si l’utilisation d’une source électrique à courant électrique s’avère né- Le soudage génère des fumées et des gaz. Leur
cessaire, se servir de la fonction de télécommande si l’appareil en est inhalation peut être dangereuse pour la santé.
équipé.
 D’autres consignes de sécurité sont nécessaires dans les conditions  Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-
suivantes : risques électriques dans un environnement humide ou si l’on peurs.
porte des vêtements mouillés ; sur des structures métalliques telles que  À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
sols, grilles ou échafaudages ; en position coincée comme assise, à ge- l’arc pour l’évacuation des fumées et des gaz de soudage.
noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou  Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu-
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser vé.
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC  Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
à tension constante (à fil), 2) un poste à souder DC manuel (électrode) les instructions du fabricant concernant les métaux, les consommables, les
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des revêtements, les nettoyants et les dégraisseurs.
situations, l’utilisation d’un poste à souder DC à fil à tension constante  Travailler dans un espace fermé seulement s’il est bien ventilé ou en
est recommandée. En outre, ne pas travailler seul ! portant un respirateur à alimentation d’air. Demander toujours à un sur-
 Couper l’alimentation ou arrêter le moteur avant de procéder veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de quant des blessures ou des accidents mortels. S’assurer que l’air de
sécurité). respiration ne présente aucun danger.
 Installer le poste correctement et le mettre à la terre convenablement  Ne pas souder dans des endroits situés à proximité d’opérations de dé-
selon les consignes du manuel de l’opérateur et les normes nationales, graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
provinciales et locales. l’arc peuvent réagir en présence de vapeurs et former des gaz haute-
ment toxiques et irritants.
 Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer  Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-
que le fil de terre du cordon d’alimentation est bien raccordé à la borne vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
de terre du sectionneur ou que la fiche du cordon est raccordée à une été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
prise correctement mise à la terre. portant un respirateur à alimentation d’air. Les revêtements et tous les
 En effectuant les raccordements d’entrée, fixer d’abord le conducteur métaux renfermant ces éléments peuvent dégager des fumées toxi-
de mise à la terre approprié et contre-vérifier les connexions. ques en cas de soudage.
OM-228 723 Page 5
 LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ
ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures
Le rayonnement de l’arc du procédé de soudage ou même la mort.
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-  Fermer l’alimentation du gaz protecteur en cas
quer des brûlures dans les yeux et sur la peau. de non-utilisation.
Des étincelles sont projetées pendant le soudage.  Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
 Porter un casque de soudage approuvé muni de verres filtrants ap- d’air homologué.
proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
 Porter des lunettes de sécurité avec écrans latéraux même sous vo- DES PIÈCES CHAUDES peuvent
tre casque.
provoquer des brûlures graves.
 Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et  Ne pas toucher des parties chaudes à mains
les étincelles ; prévenir toute personne sur les lieux de ne pas nues.
regarder l’arc.  Prévoir une période de refroidissement avant
 Porter des vêtements confectionnés avec des matières résistantes d’utiliser le pistolet ou la torche.
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.  Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
LE SOUDAGE peut provoquer un pour éviter les brûlures.
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut LES CHAMPS MAGNÉTIQUES peuvent
provoquer leur éclatement. Des étincelles peuvent affecter les stimulateurs cardiaques.
être projetées de l’arc de soudure. La projection  Porteurs de stimulateur cardiaque, rester
d’étincelles, des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de à distance.
l’électrode avec des objets métalliques peut provoquer des étincelles,  Les porteurs d’un stimulateur cardiaque doi-
une explosion, une surchauffe ou un incendie. Avant de commencer vent d’abord consulter leur médecin avant de
le soudage, vérifier et s’assurer que l’endroit ne présente pas de s’approcher des opérations de soudage à l’arc,
danger. de gougeage ou de soudage par points.
 Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi- LE BRUIT peut endommager l’ouïe.
gneusement avec des protections homologuées.
 Ne pas souder dans un endroit où des étincelles peuvent tomber sur Le bruit des processus et des équipements peut
des substances inflammables. affecter l’ouïe.
 Se protéger, ainsi que toute autre personne travaillant sur les lieux,  Porter des protections approuvées pour les
contre les étincelles et le métal chaud.
oreilles si le niveau sonore est trop élevé.
 Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
 Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
LES BOUTEILLES peuvent exploser
extincteur à la portée de main. si elles sont endommagées.
 Le soudage effectué sur un plafond, plancher, paroi ou séparation Des bouteilles de gaz protecteur contiennent du gaz
peut déclencher un incendie de l’autre côté. sous haute pression. Si une bouteille est endomma-
 Ne pas effectuer le soudage sur des conteneurs fermés tels que des gée, elle peut exploser. Du fait que les bouteilles de
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa- gaz font normalement partie du procédé de soudage,
rés correctement conformément à AWS F4.1 (voir les normes de les manipuler avec précaution.
sécurité).
 Brancher le câble de masse sur la pièce le plus près possible de la  Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
zone de soudage pour éviter le transport du courant sur une longue ve, des chocs mécaniques, des dommages physiques, du lai-
distance par des chemins inconnus éventuels en provoquant des tier, des flammes ouvertes, des étincelles et des arcs.
risques d’électrocution, d’étincelles et d’incendie.  Placer les bouteilles debout en les fixant dans un support sta-
 Ne pas utiliser le poste de soudage pour dégeler des conduites tionnaire ou dans un porte-bouteilles pour les empêcher de tom-
gelées. ber ou de se renverser.
 En cas de non-utilisation, enlever la baguette d’électrode du porte-  Tenir les bouteilles éloignées des circuits de soudage ou autres
électrode ou couper le fil à la pointe de contact. circuits électriques.
 Porter des vêtements de protection exempts d’huile tels que des  Ne jamais placer une torche de soudage sur une bouteille à gaz.
gants en cuir, une veste résistante, des pantalons sans revers, des  Une électrode de soudage ne doit jamais entrer en contact avec
bottes et un casque. une bouteille.
 Avant de souder, retirer toute substance combustible de ses poches  Ne jamais souder une bouteille pressurisée − risque d’explosion.
telles qu’un allumeur au butane ou des allumettes.  Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
 Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B tuyaux et raccords convenables pour cette application spécifi-
pour travaux de soudage et prévoir un détecteur d’incendie et un ex- que ; les maintenir ainsi que les éléments associés en bon état.
tincteur à proximité.  Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
DES PARTICULES VOLANTES  Le couvercle du détendeur doit toujours être en place, sauf lors-
peuvent blesser les yeux. que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
 Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage  Utiliser les équipements corrects, les bonnes procédures et suf-
génèrent des étincelles et des particules fisamment de personnes pour soulever et déplacer les bouteil-
les.
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent  Lire et suivre les instructions sur les bouteilles de gaz comprimé,
de projeter du laitier. l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécuri-
 Porter des lunettes de sécurité avec écrans latéraux ou un écran té.
facial.

OM-228 723 Page 6

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent

SION. provoquer des blessures.
 Ne pas placer l’appareil sur, au-dessus ou  S’abstenir de toucher des organes mobiles tels
à proximité de surfaces inflammables. que des ventilateurs.
 Ne pas installer l’appareil à proximité de  Maintenir fermés et verrouillés les portes,
produits inflammables. panneaux, recouvrements et dispositifs de
 Ne pas surcharger l’installation électrique − s’assurer que protection.
l’alimentation est correctement dimensionnée et protégée avant  Seules des personnes qualifiées sont autorisées à enlever les
de mettre l’appareil en service. portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
 Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
LA CHUTE DE L’APPAREIL peut l’alimentation électrique.
blesser.
 Utiliser l’anneau de levage uniquement pour LIRE LES INSTRUCTIONS.
soulever l’appareil, NON PAS les chariots, les  Lire le manuel d’utilisation avant d’utiliser ou
bouteilles de gaz ou tout autre accessoire. d’intervenir sur l’appareil.
 Utiliser un équipement de levage de capacité  Utiliser uniquement des pièces de rechange
suffisante pour lever l’appareil. Miller/Hobart.
 En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil. LE RAYONNEMENT HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
L’EMPLOI EXCESSIF peut SUR-  Le rayonnement haute fréquence (HF) peut
CHAUFFER L’ÉQUIPEMENT. provoquer des interférences avec les équipe-
 Prévoir une période de refroidissement ; ments de radio-navigation et de communica-
respecter le cycle opératoire nominal. tion, les services de sécurité et les ordinateurs.
 Réduire le courant ou le facteur de marche  Demander seulement à des personnes qualifiées familiarisées
avant de poursuivre le soudage. avec des équipements électroniques de faire fonctionner l’instal-
lation.
 Ne pas obstruer les passages d’air du poste.
 L’utilisateur est tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
 Si le FCC signale des interférences, arrêter immédiatement
LES CHARGES ÉLECTROSTATIQUES l’appareil.
peuvent endommager les circuits  Effectuer régulièrement le contrôle et l’entretien de l’installation.
imprimés.  Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
 Établir la connexion avec la barrette de terre distance correcte et utiliser une terre et un blindage pour réduire
avant de manipuler des cartes ou des pièces. les interférences éventuelles.
 Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
 L’énergie électromagnétique peut gêner le
DES ORGANES MOBILES peuvent fonctionnement d’appareils électroniques
provoquer des blessures. comme des ordinateurs et des robots.
 Ne pas s’approcher des organes mobiles.  Veiller à ce que tout l’équipement de la zone de
soudage soit compatible électromagnétiquement.
 Ne pas s’approcher des points de coincement
 Pour réduire la possibilité d’interférence, maintenir les câbles de
tels que des rouleaux de commande. 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 équipe-
LES FILS DE SOUDAGE peuvent ment électronique sensible.
provoquer des blessures.  Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
 Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.  En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
 Ne pas diriger le pistolet vers soi, d’autres mentaires telles que le déplacement du poste, l’utilisation de
personnes ou toute pièce mécanique en enga- câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-
geant le fil de soudage. teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

 Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :
fumées et des gaz qui contiennent des produits chimiques dont  Les gaz d’échappement des moteurs contiennent des produits
l’État de Californie reconnaît qu’ils provoquent des malformations chimiques dont l’État de Californie reconnaît qu’ils provoquent
congénitales et, dans certains cas, des cancers. (Code de santé et des cancers et des malformations congénitales ou autres pro-
de sécurité de Californie, chapitre 25249.5 et suivants) blèmes de procréation.
 Les batteries, les bornes et autres accessoires contiennent du Pour les moteurs diesel :
plomb et des composés à base de plomb, produits chimiques  Les gaz d’échappement des moteurs diesel et certains de leurs
dont l’État de Californie reconnaît qu’ils provoquent des can- composants sont reconnus par l’État de Californie comme
cers et des malformations congénitales ou autres problèmes de provoquant des cancers et des malformations congénitales ou au-
procréation. Se laver les mains après manipulation. tres problèmes de procréation.
OM-228 723 Page 7
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet :
ternet : www.global.ihs.com). www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard AWS ANSI Standard Z87.1, de American National Standards Institute, 11 West
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site 42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.global.ihs.com). Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite OSHA, Occupational Safety and Health Standards for General Industry,
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
: www.cganet.com). Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de souda- 2. Disposer les câbles d’un côté et à distance de l’opérateur.
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche votre corps.
de 17 ans, un comité spécial ruban bleu du National Research Council a
4. Garder le poste de soudage et les câbles le plus loin possible de
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
vous.
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ». 5. Connecter la pince sur la pièce aussi près que possible de la sou-
Toutefois, des études sont toujours en cours et les preuves continuent à
dure.
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux En ce qui concerne les stimulateurs cardiaques
champs électromagnétiques pendant le soudage ou le coupage. Les porteurs de stimulateur cardiaque doivent consulter leur médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-
les procédures suivantes : cin approuve, il est recommandé de suivre les procédures précédentes.

OM-228 723 Page 8

 SECTION 3 − INSTALLATION
3-1. Specifications
A. 220-230/460-575 Volts Model
Welding Input Rated Welding Maximum Amperes Input At Rated
Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
220 230 460 575
280 A @
31.2 VDC,
35.0 34.2 17.8 14.7 14.6 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.3 22.5 11.7 9.7 9.6 6.4
100 % (343 mm)
Stick Duty Cycle W: 7
7-1/2
1/2 in 41 lb
77 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 10.1 6.6 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
32.7 32.0 n/a n/a 7.3 4.6
100 %
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.
 Exceeding duty cycle can
damage unit and void
warranty.

221 587-A

200 A @ 50% Duty Cycle For Single Phase Operation 280 A @ 35% Duty Cycle For 3 Phase Operation

5 Minutes Welding 5 Minutes Resting 3-1/2 Minutes Welding 6-1/2 Minutes Resting

Overheating
0 A or V

15
OR
Minutes Reduce Duty Cycle

OM-217 655 Page 9

3-3. Stick (SMAW) Volt-Ampere Curves
xx10 Stick VA Curves Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
100 shown.

90

80

70

60
DC VOLTS

575V Primary
50

40
208V Primary
30

20
280A
STIFF
10
30A SOFT 30A STIFF 280A SOFT
0
0 50 100 150 200 250 300 350 400 450
DC AMPS

xx18 Stick VA Curve

100

90

80
575V Primary
70

60
DC VOLTS

50

40 208V Primary

30

20

10 30A 30A STIFF 280A

280A SOFT
SOFT STIFF
0
0 50 100 150 200 250 300 350 400
DC AMPS

Ref. 221 588-A

OM-217 655 Page 10

3-4. TIG (GTAW) Volt-Ampere Curve
Volt-ampere curves show minimum
TIG VA Curve and maximum voltage and
amperage output capabilities of
80 welding power source. Curves of
other settings fall between curves
70 shown.

60

50
DC VOLTS

40

30

20

10

0
0 50 100 150 200 250 300
DC AMPS

Ref. 221 588-A

OM-217 655 Page 11

3-5. Selecting A Location
1 Line Disconnect Device
Locate unit near correct input
power supply.
Dimensions And Weight  Special installation may be
40 lb (18.2 kg) - with power cord required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
18 in
Section 20.
(457 mm)

13-1/2 in
(343 mm)

7-1/2 in
(191 mm)

Location And Airflow

18 in
(460 mm)

18 in
(460 mm)

803 942-A

OM-217 655 Page 12

3-6. Weld Output Terminals And Selecting Cable Sizes*

 ARC WELDING can cause Electromagnetic Interference.

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 electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. 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.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
 Turn off power before 10 −
60 − 100%
connecting to weld out- Welding 60%
Duty 10 − 100% Duty Cycle
put terminals. Amperes*** Duty
Cycle
 Do not use worn, dam- Cycle
aged, undersized, or
poorly spliced cables.

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
+ −
Output Receptacles 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***Select weld cable size for pulsing application at peak amperage value. S-0007-F−803 080

OM-217 655 Page 13

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
5
Terminal
6 Connect TIG torch to negative weld
output terminal.

3 3 Gas Cylinder
4 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5 Regulator/Flowmeter
6 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)

803 943-A

OM-217 655 Page 14

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.

803 944-A

3-9. Electrical Service Guide

 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
generator input power to this welding power source.

NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, inadvertent shutdown may occur.

50/60 Hz Single-
50/60 Hz Three-Phase,
Phase, 50% Duty
35% Duty Cycle
Cycle

Input Voltage 220 230 220 230 460 575

Input Amperes At Rated Output 43.9 43.0 35.0 34.2 17.8 14.7

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay 2 50 50 45 45 20 15

Normal Operating 3 70 70 60 50 25 20

Min Input Conductor Size In AWG4 8 8 10 10 14 14

129 141 123 196 306

Max Recommended Input Conductor Length In Feet (Meters) 113 (34)
(39) (43) (38) (60) (93)

Min Grounding Conductor Size In AWG4 8 8 10 10 14 14

Reference: 2005 National Electrical Code (NEC) (including article 630)

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).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
 Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
OM-217 655 Page 15
3-10. Selecting 220 - 230 Volts AC Single/Three Phase Input Voltage
1  Turn Off welding power
source, and disconnect
input power before
proceeding.
Check input voltage available at
site.
220−230 460−575
1 Switch Cover
VAC VAC
2 Voltage Selection Switch
The input voltage that the power
2 source is linked for is labeled next to
the switch.
Check voltage selected on unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
 Do not switch under load.
To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position

at 905 straight up.
Be sure that switch is turned
completely to its detent position.
Tools Needed:

Ref. 803 946-A

3-11. Selecting 460 - 575 Volts AC Three Phase Input Voltage

1  Turn Off welding power
source, and disconnect
input power before
proceeding.
Check input voltage available at
site.
220−230 460−575 1 Switch Cover
VAC VAC
2 Voltage Selection Switch
The input voltage that the power
source is linked for is labeled next to
2 the switch.
Check voltage selected on unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
 Do not switch under load.
To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position

at 905 straight up.
Be sure that switch is turned
completely to its detent position.

Tools Needed:

Ref. 803 946-A

OM-217 655 Page 16

3-12. Connecting 1-Phase Input Power
 Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
 Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
 Always connect green or green/
1 yellow conductor to supply
grounding terminal first, and never
to a line terminal.
See rating label on unit and check input
8 =GND/PE Earth Ground voltage available at site.
1 Black And White Input Conductor
(L1 And L2)
10
2 Red Input Conductor
3 Green Or Green/Yellow Grounding
Conductor
7 4 Insulation Sleeving
5 Electrical Tape
9 Insulate and isolate red conductor as
shown.
6 Input Power Cord.
L1 7 Disconnect Device (switch shown in
1
L2 the OFF position)
3 8 Disconnect Device Grounding
Terminal
1 9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
6 conductor to disconnect device grounding
terminal first.
2 Connect input conductors L1 and L2 to
disconnect device line terminals.
3
10 Over-Current Protection
Select type and size of over-current
6 protection using Section 3-9 (fused dis-
connect switch shown).
4
5 Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

803 766-A / 803 942-A

OM-217 655 Page 17

3-13. Connecting 3-Phase Input Power
 Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.

3  Disconnect and lockout/tagout in-

put power before connecting input
conductors from unit.
 Always connect green or green/
= GND/PE Earth Ground yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4 See rating label on unit and check input
voltage available at site.
1 Input Power Cord.
2 Disconnect Device (switch shown in
7 the OFF position)
3 Green Or Green/Yellow Grounding
Conductor
4 Disconnect Device Grounding
Terminal
5 Input Conductors (L1, L2 And L3)
2
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
L1 7 Over-Current Protection

3 Select type and size of over-current

L2 5
protection using Section 3-9 (fused dis-
connect switch shown).
6 L3
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

803 766-A / 803 942-A

OM-217 655 Page 18

 SECTION 4 − OPERATION
4-1. Controls

2 5 3 4

NOTE: Green on nameplate indicates a TIG 2 Output Indicator Light 4 Amperage Control
function, Gray indicates a Stick function. When unit is first energized this indicator See Section 4-5.
1 Power Switch light flashes several times and then 5 High Temperature Shutdown Light
illuminates continuously. When unit is shut When unit is first energized this indicator
Use switch to turn unit and indicator light down, the indicator light flashes several
On/Off. light illuminates for approximately 1 second
times and the cooling fan will run briefly, to provide visual confirmation that the light
then both will turn off completely. is functioning properly (see Section 3-2).
3 Process Control 6 Remote 14 Receptacle
See Section 4-2.

Ref. 217 192-A / 803 942-A

OM-217 655 Page 19

4-2. Process Select Control
1 Process Select Control
Rotate knob to select desired
process.
Lift-Arc TIG - Normal
1 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,
preventing overheating, sticking, or
contaminating the electrode (see
Section 4-4). Make connections
according to Section 3-7.
Stick E XX18 Soft - This setting
provides a lower dig/arc force
setting for smooth weld perfor-
mance. A stable weld puddle with
little arc “snap” gives excellent weld
bead appearance with minimal
spatter. Make connections
according to Section 3-8.
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
Section 3-8.
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.
RECOMMENDED PROCESS Make connections according to
SELECTIONS VS ELECTRODE TYPE Section 3-8.
Stick E XX10 Stiff - This setting
ELECTRODE SUGGESTED PROCESS provides a higher dig/arc force for
TYPE SETTING open root vertical down joints
where additional current is needed
EXXX1 EXX10 to compensate for tight joint fit up
EXXX2 EXX10 without the need to increase overall
welding current. Make connections
according to Section 3-8.
EXXX3 EXX18
EXXX4 EXX18
EXXX5 EXX18
EXXX6 EXX18
EXXX7 EXX18
EXXX8 EXX18
STAINLESS EXX18

OM-217 655 Page 20

4-3. Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as
follows:
1 Electrode
2 Workpiece
3 Arc
1 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.
2 VRD Model Only: Normal
open-circuit voltage is not present
before electrode touches workpiece;
3 only a low sensing voltage is present
between electrode and workpiece.
This allows electrode to touch
workpiece without overheating,
sticking, or getting contaminated.

4-4. Lift-Arc™ Start Procedure

Lift-Arc Start
With Lift-Arc selected, start arc
as follows:
1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
Lift-Arc Start Method workpiece for 1-2 seconds, and
1 2 slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
1−2 electrode and workpiece. The
“Touch” Seconds 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.
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-217 655 Page 21

4-5. Amperage Control
1 AMP ADJUST (Amperage
Control)
1
Rotate knob clockwise to increase
amperage (5-280 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 L N H A 15 volts dc (not functional).
D M G 15 VOLTS DC
E F B Contact closure to A completes 15 volts dc
contactor control circuit (not functional).

C Output to remote control; 0 to +10 volts dc.

REMOTE D Remote control circuit common.

OUTPUT
CONTROL
E 0 to +10 volts dc input command signal from
remote control.

K Chassis common.
803 942-A GND

*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-221 611.

OM-217 655 Page 22

 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING

5-1. Routine Maintenance

 Disconnect power before maintaining.

 Maintain more often during severe conditions.

3 Months

Replace Clean and tighten Replace Damaged

unreadable weld terminals. Gas Hose
labels.

3 Months

Repair Or Replace
Cracked Cables
And Cords

6 Months
 Do not remove case when
blowing out inside of unit
(see Section 5-2) .
Blow out inside. During
heavy service clean
monthly.

5-2. Blowing Out Inside Of Unit

 Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.

803 942-A

OM-217 655 Page 23

5-3. Troubleshooting
1 Output LED (Blue)
2 High Temperature LED
(Yellow)

803 942-A

Repeated LED Flashes Indicate

Status
Red (LED3
Blue Yellow Trouble Possible Causes Remedy
on PC3)
Place line disconnect switch in
Line Disconnect open. on position (see Section 3-12 or
3-13).
Check and replace line fuses, if
No weld output; necessary, or reset circuit
None None None unit completely Blown fuses.
breaker (see Section 3-12 or
inoperative. 3-13).
Check for proper input connec-
Improper input connections.
tions (see Section 3-10 or 3-11).
Fuse F1 on PC2 blown. Check and replace F1.
Line voltage too high or
Line voltage must be ±10%.
too low.

Flashes Con- Check line voltage and link ac-

0 7 No weld output. Not ready. Unit is linked incorrectly.
tinuously cordingly.
Check DC buss caps and PC2,
Buss voltage imbalance.
and replace if necessary.
Check CT1 and wiring for an
No primary lfb.
open condition.
Check for shorts or opens in
Failed output diode(s).
wiring.

6 0 1 No weld output. Current latch. Replace boost inductor if neces-

Failed boost inductor.
sary.
Failed LEM. Replace LEM if necessary.
Open connection be- Inspect all wiring and connec-
tween LEM and PC1. tions.
Check for a shorted relay or wir-
Shorted boost relay.
ing.
Boost relay does not
deenergize after termina- Check PC1.
4 0 8 No weld output. Voltage latch. tion of weld.
Voltage in excess of
100V from another Check for external voltage
source applied across sources.
output studs.

OM-217 655 Page 24

Repeated LED Flashes Indicate
Status
Red (LED3
Blue Yellow Trouble Possible Causes Remedy
on PC3)
Vfb leads not connected Check Vfb leads for proper wir-
or reversed. ing and connection.
Short circuit across out-
5 0 11 No weld output. Voltage loss. Check for shorts.
put studs.
Check PC2 and replace if nec-
Failed IGBT on PC2.
essary.

Output fold- Single phase rating ex- Reduce output to 200 amperes
Reduced weld back due to ceeded. or less.
2 0 6
output. excessive in- High output VA coupled Check line voltage and weld
put current. with a low 230V line. settings.
Remove trigger, wait approxi-
3 0 10 Remote trigger has been left on.
mately 5 seconds, and restart.
Primary (IGBT) thermis- Allow unit to cool down.
3 No weld output.
On Unit over
over- tor over temperature. Retorque PM1, PM2, and PM3
0
continuously heated. Secondary thermistor mounting hardware to 25 in lbs
5 (2.8 Nm).
over temperature.
Shorted primary (IGBT) Check IGBT thermistors for
0
thermistor. shorts.
Open primary (IGBT) Check IGBT thermistors and
2
thermistor. associated wiring for opens.
Flashes Thermistor Check thermistor on output
0 No weld output. Open secondary thermis-
continuously 4 failure. heatsink and associated wiring
tor.
for opens.
Check thermistor on ouput heat-
Shorted secondary
9 sink and associated wiring for
thermistor.
shorts.
Check for and remove anything
Blocked fan.
Fan not operat
operat- blocking fan movement.
N/A N/A N/A
ing. Have factory authorized service
Fan failure.
agent check fan motor.
Use proper size and type of
Weld cables too small or defective.
Erratic or im
im- weld cables (see Section 3-6).
N/A N/A N/A proper weld Clean and tighten all weld cable
output. Dirty or loose connections. connections (see Section 3-7 or
3-8).
Use proper size tungsten (see
Improper tungsten.
Section 7-1).
Use properly prepared tungsten
N/A N/A N/A Wandering arc. Worn or defective tungsten.
(see Section 7-3).
Reduce gas flow rate (see Sec-
Gas flow too high.
tion 3-7).
Gas is blown away from weld zone. Shield weld zone from drafts.
Tungsten elec- Allow adequate postflow time to
trode oxidizing Inadequate postflow time. shield tungsten while it is cool-
and not remain- ing after welding stops.
N/A N/A N/A ing bright after
conclusion of Check and tighten all gas fit-
Loose or leaking gas fittings.
weld. tings (see Section 3-7).
Water in torch. Refer to torch manual.

OM-217 655 Page 25

 SECTION 6 − ELECTRICAL DIAGRAMS

Figure 6-1. Circuit Diagram

OM-228 723 Page 26

 Ref. 217 589-B

OM-228 723 Page 27

 SECTION 7 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE
gtaw 7/97

NOTE 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.

7-1. Selecting Tungsten Electrode

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC − Argon − Electrode DC − Argon − Electrode AC − Argon − Using AC − Argon − Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
2% Thorium Alloyed
Tungsten (Red Band)
.010” Up to 25 * Up to 20 Up to 15
.020” 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525

♦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

 Grinding the tungsten elec-
trode produces dust and fly-
ing sparks which can cause
injury and start fires. Use lo-
1 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
electrodes contains low-lev-
2 el radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1 Tungsten Electrode With
Balled End
2 Pointed Tungsten Electrode

Ref. S-0161

OM-228 723 Page 28

7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1 Tungsten Electrode
1 2 2 Tapered End
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 Stable Arc
2 Flat
1
Diameter of this flat determines
amperage capacity.
2
3 Grinding Wheel
3 Grinding wheel should be dedi-
cated to grinding tungsten only.
4 Straight Ground

4
Ideal Tungsten Preparation − Stable Arc

1 Arc Wander
2 Point
1 3 Grinding Wheel
Grinding wheel should be dedi-
2 cated to grinding tungsten only.
4 Radial Ground

Wrong Tungsten Preparation − Wandering Arc

Ref. S-0161 / Ref. S-0162

OM-228 723 Page 29

 SECTION 8 − PARTS LIST

 Hardware is common and

not available unless listed.

10 8

24
18
17

15 15

6 11

23

22
13
13
12 20

30 7 26

21
16
9
14
3

19 2

16

25

803 947-B

Figure 8-1. Main Assembly

OM-228 723 Page 30
 Item Dia. Part
No. Mkgs. No. Description Qty.

Figure 8-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 221585 .. PANEL, FRONT W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 221586 .. PANEL, REAR W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 212809 .. MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 206037 .. 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 . . . . . . . . . . . . . +217216 .. WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 203572 .. LABEL, WARN GEN PRECAUTION STATIC&WIREFEED (FRENCH) . . 1
. . . 9 . . . . . . . . . . . . . +207437 .. CABLE, POWER 6 FT 10GA 4C BLK/RED/WHT/GRNYEL . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 220885 .. LABEL, WARNING ELECTRIC SHOCK POWER CORD (FR) . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 206108 .. HANDLE, RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 206289 .. LINK, CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . PLG3 . . . . . 206247 .. PLUGS, W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . PLG4 . . . . . 206254 .. PLUGS, W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 196231 .. XFMR, CURRENT SENSING 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 206270 .. INSULATOR, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . PLG5 . . . . . 206276 .. CABLE, LEM W/PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . C1,C2 . . . . +203912 .. CAPACITOR, ELCTLT 2400 UF 500 VDC CAN 2.5 DIA . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 218544 .. LABEL, WARNING ELECTRIC SHOCK CAN KILL (FRENCH) . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . 205908 .. CLAMP, CAPACITOR 2.500 DIA HORIZONTAL MTG NYLON . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 189777 .. RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . PC2 . . . . . . 222447 .. KIT, CIRCUIT CARD ASSY INTERCONNECT . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . PC1 . . . . . . 221472 .. CIRCUIT CARD ASSY, POWER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 217587 .. FUSE, CRTG 2. AMP 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 176879 .. SCREW, M 5− .8X 12 HEX HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . . 207113 .. WASHER, CONE .205IDX0.394ODX.015T STL . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . . 200550 .. SCREW, M10−1.5X 20 HEX HD−PLN 8.8 PLD SEMS . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . 217249 .. SWITCH ASSY, RELINKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-228 723 Page 31

  Hardware is common and 8
not available unless listed.
19 20

4 24
7
2
18

14
23

9
13
12
4
6 22 15
5 3
7

17
11
21 16

10 803 158-A

Figure 8-2. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 8-2. Panel, Front w/Components

... 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 . . . . . . . . . . . . . . . 3
... 9 . . . . . . . . . . . . . . 178548 . . TERMINAL, CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 10 . . . . . . . . . . . . . . 202553 . . RECEPTACLE, TWIST LOCK DINSE (FEMALE) . . . . . . . . . . . . . . . . . . . . 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 ........................ NAMEPLATE (ORDER BY MODEL AND SERIAL NUMBER) . . . . . . . . . 1
... 19 . . . PC4 . . . . . . 205764 . . CIRCUIT CARD ASSY, OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . 1
... 20 . . . PC3 . . . . . . 221467 . . CIRCUIT CARD ASSY, PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . . 170391 . . CONNECTOR, CIRC MS PROTECTIVE CAP . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . . . . . . . . . . 178355 . . NUT, 375−32 .54HEX .25H NYL FLANGE .62D . . . . . . . . . . . . . . . . . . . . . 2
... 23 . . . . . . . . . . . . . . 209554 . . SCREW, KA35X 8 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 24 . . . . . . . . . . . . . 097 132 . . STAND−OFF, NO 6−32 X .375 LG .250 HEX BRS M&F . . . . . . . . . . . . . . 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-228 723 Page 32
  Hardware is common and
not available unless listed.

2
3
803 948-A

Figure 8-3. Panel, Rear w/Components

Item Part
No. No. Description Quantity

Figure 8-3. Panel, Rear w/Components

... 1 . . . . . . . . . . 194242 .. PANEL, FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . 206053 .. PANEL, REAR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . 210128 .. BRACKET, HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . 145217 .. SCREW, K40X 12 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . 207253 .. BLANK, HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . 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-228 723 Page 33

  Hardware is common and 10
not available unless listed.

8
11

13

8
1
12

5
2
4 804 206-A

Figure 8-4. Magnetics Subassembly

Item Diagram Part

No. Marking No. Description Quantity

Figure 8-4. Magnetics Subassembly

... 1 .............. 206063 .. PANEL, PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . T1 . . . . . . 206065 .. 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 . . . . L3 . . . . . . 225189 .. COIL, INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 .............. 198634 .. BRACKET, FRONT HEATSINK MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 .............. 083147 .. GROMMET, SCR NO 8/10 PANEL HOLE .312 SQ .500 HIGH . . . . . . . . . 1
... 12 .............. 136343 .. SCREW, K50X 20 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 .............. 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-228 723 Page 34

  Hardware is common and
not available unless listed.

3 803 949-B

Figure 8-5. Relinking Switch And Door Assembly

Item Part
No. No. Description Quantity

Figure 8-5. Relinking Switch And Door Assembly

. . . 1 . . . . . . . . . . . . . +217252 .. DOOR ASSY, RELINKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 228675 .. LABEL, VOLTAGE SWITCH POSITION 220−230/460−575 . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 228308 .. LABEL, CAUTION OPERATING LINK SWITCH ETC (FRENCH) . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 217647 .. SWITCH, ROTARY 3 POSN 4P 32A 600V 180 DEG (SPL) . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 209554 .. SCREW, KA35X 8 PAN HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 221573 .. NUT, SPEED SNAP−IN 1/4 TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . 221575 .. RETAINER, NYLON PUSH−ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 221574 .. SCREW, 1/4 TURN OVAL HD−PHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-228 723 Page 35

  Hardware is common and 10
not available unless listed.
11
12
12

7
6
2

9
3
8

803 159-D

Figure 8-6. Heat Sink Assembly, Output Diode

Item Diagram Part

No. marking No. Description Quantity

Figure 8-6. Heat Sink Assembly, Output Diode

... 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 . . 209223 .. 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 . . . . . . . . . . 207451 .. SCREW, 008−32X .50 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . 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-228 723 Page 36

  Hardware is common and
not available unless listed.

1
6
7
8

2
5

803 160

Figure 8-7. Base Assembly

Item Diagram Part

No. marking No. Description Quantity

Figure 8-7. Base Assembly

... 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-228 723 Page 37

  Hardware is common and
not available unless listed.

803 162-B

Figure 8-8. Heat Sink Assembly, Input

Item Diagram Part

No. marking No. Description Quantity

Figure 8-8. Heat Sink Assembly, Input

. . . 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-228 723 Page 38

 Effective January 1, 2006
(Equipment with a serial number preface of “LG” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Replacement Parts (No labor)
Within the warranty periods listed below, Miller will repair or * Spoolmate Spoolguns
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which Miller’s True Blue® Limited Warranty shall not apply to:
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings, relays
reliable response you Miller shall honor warranty claims on warranted equipment listed or parts that fail due to normal wear. (Exception:
need. Most replacement below in the event of such a failure within the warranty time brushes, slip rings, and relays are covered on Bobcat,
parts can be in your periods. All warranty time periods start on the date that the Trailblazer, and Legend models.)
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others, such
year after the equipment is sent to a North American distributor as engines or trade accessories. These items are covered
Support or eighteen months after the equipment is sent to an by the manufacturer’s warranty, if any.
Need fast answers to the International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
Contact your distributor.
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
distributor and Miller is 2. 3 Years — Parts and Labor
necessary maintenance, or equipment which has been
there to help you, every * Transformer/Rectifier Power Sources used for operation outside of the specifications for the
step of the way. * Plasma Arc Cutting Power Sources equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Field Options BY MILLER.
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
* Bernard-Branded Mig Guns (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns/TIG Torches and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2006−01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

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.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com

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 © 2006 Miller Electric Mfg. Co. 2006−01