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Visit our website at

www.MillerWelds.com

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Arc Welding Power Source

OM-356 188694ZJune 2004

Syncrowave 350 LX

And Non-CE Models

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Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank youand congratulationson choosing Miller. Now you can get

the job done and get it done right. We know you dont have time to do

it any other way.

Thats 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 couldnt 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. Theyre just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 7/03

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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 SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Autres symboles relatifs l installation, au fonctionnement et l entretien de lappareil. 7. . . . . . . . . . .2-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Torch/Cable Holder Label 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Weld Cable Connection Label 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Manufacturers Rating Label For CE Products 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5. Symbols And Definitions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Selecting A Location 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Dimensions And Weights 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Specifications 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Duty Cycle And Overheating 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Volt-Ampere Curves 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Weld Output Terminals And Selecting Cable Sizes 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Remote 14 Receptacle 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Electrical Service Guide 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Placing Jumper Links 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11. Connecting Input Power 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 5 OPERATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Output Selector Switch 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Process Control 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Current Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Output Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Start Mode 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Meters 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8. Amperage Adjustment Control 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9. Balance/DIG Control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10. Preflow Time Control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11. Postflow Time Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12. Setting Pulse Controls 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13. Optional Sequence Controls 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14. Sequence Selection Switch 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15. Start Time/Spot Time Control And Start Current Control 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16. Crater Time Control And Final Current Control 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17. Start/Crater Sequence Controls 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18. 4T Sequence Selection Controls 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19. Spot Time Control 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20. Timer/Cycle Counter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 6 MAINTENANCE & TROUBLESHOOTING 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Circuit Breaker CB1 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Adjusting Spark Gaps 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Voltmeter/Ammeter Help Displays 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 HIGH FREQUENCY 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1. Welding Processes Requiring High Frequency 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2. Incorrect Installation 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3. Correct Installation 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 PARTS LIST 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIESWARRANTY

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dec_con1_11/02

Declaration of Conformity ForEuropean Community (CE) Products

This information is provided for units with CE certification (see rating label on unit.)NOTE

Manufacturers Name: Miller Electric Mfg. Co.Manufacturers Address: 1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product: Syncrowave 350LXconforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Electromagnetic Capability Directives: 89/336, 92/31/EEC

Standards

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990

Arc Welding Equipment Part 1: Welding Power Sources: IEC 609741(November 1997 Draft revision)

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Insulation coordination for equipment within low-voltage systems:Part 1: Principles, requirements and tests: IEC 664-1: 1992

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:EN50199: August 1995

European Contact: Mr. Danilo Fedolfi, Managing DirectorITW WELDING PRODUCTS ITALY S.r.l.Via Privata Iseo 6/E20098 San GiulianoMilanese, Italy

Telephone: 39(02)98290-1Fax: 39(02)98290-203

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Notes

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OM-356 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/03

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Marks a special safety message.

Means Note; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit. During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.

Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present onunit.

Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

Always verify the supply ground check and be sure that input

power cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

When making input connections, attach proper grounding conduc-tor first double-check connections.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directlywith a separate cable.

Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.

If ventilation is poor, use an approved air-supplied respirator.

Read the Material Safety Data Sheets (MSDSs) and themanufacturers instructions for metals, consumables, coatings,cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.

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OM-356 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.

Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use. Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on gun ortorch.

MAGNETIC FIELDScan affect pacemakers.

Pacemaker wearers keep away. Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is inuse or connected for use.

Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in Safety

Standards.

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OM-356 Page 3

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

FIRE OR EXPLOSION hazard.

Do not install or place unit on, over, or nearcombustible surfaces.

Do not install unit near flammables.

Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift andsupport unit.

If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle beforestarting to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handlingboards or parts.

Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

Keep away from moving parts. Keep away from pinch points such as driverolls.

WELDING WIRE can cause injury.

Do not press gun trigger until instructed to doso.

Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunicat ions equipment.

Have only qualified persons familiar withelectronic equipment perform this installation.

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 theequipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

Be sure all equipment in the welding area is

electromagnetically compatible. To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-tronic equipment.

Be sure this welding machine is installed and groundedaccording to this manual.

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

For Gasoline Engines: Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductiveharm.

For Diesel Engines: Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andother reproductive harm.

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1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,ANSI Standard Z49.1,from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA022699101 (phone: 6177703000, website: www.nfpa.org and www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:8004636727or in Toronto 4167474044, website: www.csain-ternational.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 100368002 (phone: 2126424900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:6177703000,website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Officesphone for Region 5, Chicago, is3123532220,website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.

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SECTION 2 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

som_fre 8/03

2-1. Signification des symboles

Signifie Mise en garde. Faire preuve de vigilance. Cette procdure prsente des risques identifis par lessymboles adjacents aux directives.

Identifie un message de scurit particulier.

Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde. Faire preuve de vigi-lance. Il y a des dangers lis aux CHOCS LECTRIQUES, auxPICES EN MOUVEMENT et aux PICES CHAUDES. Se reporteraux symboles et aux directives ci-dessous afin de connatre les me-sures prendre pour viter tout danger.

2-2. Dangers relatifs au soudage larc

Les symboles ci-aprs sont utiliss tout au long du prsentmanuel pour attirer lattention sur les dangers potentiels et lesidentifier. Lorsquon voit un symbole, faire preuve de vigilance etsuivre les directives mentionnes afin dviter tout danger. Lesconsignes de scurit nonces ci-aprs ne font que rsumer lecontenu des normes de scurit mentionnes la section 2-4.Lire et respecter toutes ces normes.

Linstallation, lutilisation, lentretien et les rparations ne doi-vent tre confis qu des personnes qualifies.

Pendant lutilisation de lappareil, tenir lcart toute personne,en particulier les enfants.

LES DCHARGES LECTRIQUESpeuvent tre mortelles.Un simple contact avec des pices sous tension peutcauser une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tensionds que lappareil est en fonctionnement. Le circuit

dentre et les circuits internes de lappareil sont galement sous tension.En soudage semiautomatique ou automatique, le fil, le dvidoir, lelogement des galets dentranement et les pices mtalliques en contactavec le fil de soudage sont sous tension. Tout matriel mal install ou malmis la terre prsente un danger.

Ne jamais toucher aux pices lectriques sous tension.

Porter des gants et des vtements de protection secs et exempts detrous. Sisoler de la pice et de la terre au moyen de tapis ou autres disposi-

tifs isolants suffisamment grands pour empcher tout contactphysique avec la pice ou la terre.

Ne pas se servir dune source de courant alternatif dans les zones humi-des, les endroits confins ou l o on risque de tomber.

Ne se servir dune source de courant alternatif QUE si le procd de souda-ge lexige.

Si lutilisation dune source de courant alternatif savre ncessaire, se ser-vir de la fonction de tlcommande si lappareil en est quip.

Couper lalimentation ou arrter le moteur avant de procder linstal-lation, la rparation ou lentretien de lappareil. Couper/tiqueterlalimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor-mes de scurit).

Installer et mettre la terre correctement lappareil conformment son manuel dutilisation et aux codes nationaux, provinciaux etmunicipaux.

Toujours vrifier la terre du cordon dalimentation Vrifier et sassu-rer que le fil de terre du cordon dalimentation est bien raccord laborne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre.

Pour excuter les branchements dentre, fixer dabord le conducteurde mise la terre adquat et contrevrifier les connexions.

Vrifier frquemment le cordon dalimentation et sassurer quil nestni endommag ni dnud ; le remplacer immdiatement sil est en-dommag tout cble dnud peut causer une lectrocution.

Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser de cbles uss, endommags, de calibre insuffisant ou

mal pisss. Ne pas senrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct. Ne pas toucher llectrode quand on est en contact avec la pice, la

terre ou une lectrode dune autre machine.

Nutiliser que du matriel en bon tat. Rparer ou remplacer surlechamp les pices endommages. Entretenir lappareil conformmentau prsent manuel.

Porter un harnais de scurit quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le cble de retour de faon obtenir un bon contact mtal surmtal avec la pice souder ou la table de travail, le plus prs possiblede la soudure.

Ne pas connecter plus dune lectrode ou plus dun cble de masse unmme terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANTdans les convertisseurs aprs la suppression delalimentation lectrique. Arrter les convertisseurs, dbrancher le courant lectrique et d-

charger les condensateurs dalimentation selon les instructionsnonces la section Entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz dontlinhalation peut tre dangereuse pour la sant.

LES FUMES ET LES GAZ peuventtre dangereux.

Se tenir distance des fumes et ne pas les inhaler.

lintrieur, ventiler la zone et/ou utiliser un dispositif daspiration auniveau de larc pour lvacuation des fumes et des gaz de soudage.

Si la ventilation est insuffisante, utiliser un respirateur adductiondair agr.

Lire les fiches techniques de santscurit (FTSS) et les instruc-tions du fabricant concernant les mtaux, les consommables, lesrevtements, les nettoyants et les dgraisseurs.

Ne travailler dans un espace clos que sil est bien ventil ou porter unrespirateur adduction dair. Demander toujours un surveillant d-ment form de se tenir proximit. Des fumes et des gaz de soudagepeuvent se substituer lair, abaisser la teneur en oxygne et causerdes lsions ou des accidents mortels. Sassurer que lair est respira-ble.

Ne pas souder proximit doprations de dgraissage, de nettoyageou de pulvrisation. La chaleur et les rayons de larc peuvent ragir enprsence de vapeurs et former des gaz hautement toxiques et irri-tants.

Ne pas souder de mtaux munis dun revtement, tels que la tledacier galvanise, plombe ou cadmie, moins que le revtementnait t enlev dans la zone de soudage, que lendroit soit bien venti-l, et si ncessaire, porter un respirateur adduction dair. Lesrevtements et tous les mtaux renfermant ces lments peuvent d-gager des fumes toxiques lorsquon les soude.

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Le rayonnement de larc gnre des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brlures oculaires et cutanes.Des tincelles sont projetes pendant le soudage.

LES RAYONS DE LARC peuvent cau-ser des brlures oculaires et cuta-nes.

Porter un masque de soudage muni dun filtre de la nuance adquatepour se protger le visage et les yeux pendant le soudage ou pour re-garder (voir les normes de scurit ANSI Z49.1 et Z87.1).

Porter des lunettes de scurit crans latraux sous le masque.

Utiliser des crans ou des barrires pour protger les tiers de lclatblouissant ou aveuglant de larc ; leur demander de ne pas regarderlarc.

Porter des vtements de protection en matire durable et ignifuge(cuir ou laine) et des chaussures de scurit.

Le soudage effectu sur des rcipients ferms tels quedes rservoirs, des fts ou des conduites peut causerleur clatement. Des tincelles peuvent tre projetesde larc de soudure. La projection dtincelles, les

pices chaudes et les quipements chauds peuvent causer desincendies et des brlures. Le contact accidentel de llectrode avec toutobjet mtallique peut causer des tincelles, une explosion, un surchauf-fement ou un incendie. Avant de commencer le soudage, vrifier etsassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut causer un incen-die ou une explosion.

Se protger et protger les tiers de la projection dtincelles et de m-

tal chaud. Ne pas souder un endroit o des tincelles peuvent tomber sur dessubstances inflammables.

Placer toutes les substances inflammables une distance de 10,7 mde larc de soudage. En cas dimpossibilit, les recouvrir soigneuse-ment avec des protections agres.

Des tincelles et des matires en fusion peuvent facilement passermme par des fissures et des ouvertures de petites dimensions.

Surveiller tout dclenchement dincendie et tenir un extincteur proxi-mit.

Le soudage effectu sur un plafond, un plancher, une paroi ou unecloison peut dclencher un incendie de lautre ct.

Ne pas souder des rcipients ferms tels que des rservoirs, des ftsou des conduites, moins quils naient t prpars conformment lAWS F4.1 (voir les normes de scurit).

Brancher le cble sur la pice le plus prs possible de la zone de sou-dage pour viter que le courant ne circule sur une longue distance, pardes chemins inconnus, et ne cause des risques dlectrocution et din-

cendie. Ne pas utiliser le poste de soudage pour dgeler des conduites ge-

les. En cas de non utilisation, enlever la baguette dlectrode du porte

lectrode ou couper le fil au raz du tubecontact. Porter des vtements de protection exempts dhuile tels que des

gants en cuir, une chemise en tissu pais, des pantalons sans revers,des chaussures montantes et un masque.

Avant de souder, retirer tout produit combustible de ses poches, telquun briquet au butane ou des allumettes.

LES PARTICULES PROJETES peu-vent blesser les yeux.

Le soudage, le burinage, le passage de la pice la brosse mtallique et le meulage provoquent

lmission dtincelles et de particules mtalli-ques. Pendant leur refroidissement, les soudures risquent de projeter dulaitier. Porter des lunettes de scurit crans latraux agrs, mme sous le

masque de soudage.

LES ACCUMULATIONS DE GAZ peu-vent causer des blessures ou mmela mort.

Couper lalimentation en gaz protecteur en cas denon utilisation.

Veiller toujours bien ventiler les espaces confins ou porter un respira-teur adduction dair agr.

LES PICES CHAUDES peuvent cau-

ser des brlures graves. Ne pas toucher les pices chaudes main nue. Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuventperturber le fonctionnement des stimu-lateurs cardiaques.

Les personnes qui portent un stimulateur cardiaquedoivent se tenir distance.

Ils doivent consulter leur mdecin avant de sappro-cher dun lieu o on excute des oprations de sou-dage larc, de gougeage ou de soudage par points.

LE BRUIT peut affecter loue.

Le bruit de certains processus et quipements peutaffecter loue.

Porter des protecteurs doreille agrs si le niveausonore est trop lev.

Les bouteilles de gaz protecteur contiennent du gazsous haute pression. Toute bouteille endommagepeut exploser. Comme les bouteilles de gaz fontnormalement partie du procd de soudage, les

manipuler avec prcaution.

Les BOUTEILLES endommagespeuvent exploser.

Protger les bouteilles de gaz comprim de la chaleur excessive, deschocs mcaniques, du laitier, des flammes nues, des tincelles et desarcs.

Placer les bouteilles debout en les fixant dans un support stationnaireou dans un portebouteilles pour les empcher de tomber ou de serenverser.

Tenir les bouteilles loignes des circuits de soudage ou autres cir-cuits lectriques.

Ne jamais poser une torche de soudage sur une bouteille de gaz. Ne jamais mettre une lectrode de soudage en contact avec une bou-

teille de gaz. Ne jamais souder une bouteille contenant du gaz sous pression elle

risquerait dexploser. Nutiliser que les bouteilles de gaz protecteur, rgulateurs, tuyaux et

raccords adquats pour lapplication envisage ; les maintenir en bontat, ainsi que les pices connexes.

Dtourner la tte lorsquon ouvre la soupape dune bouteille.

Laisser le capuchon protecteur sur la soupape, sauf en cas dutilisa-tion ou de branchement de la bouteille

Lire et suivre les instructions concernant les bouteilles de gaz compri-m, les quipements associs et les publications P1 de la CGA,mentionnes dans les normes de scurit.

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2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien delappareil.

Risque DINCENDIE OU DEXPLO-SION

Ne pas placer lappareil sur une surface inflam-mable, ni audessus ou proximit delle.

Ne pas installer lappareil proximit de produits inflammables.

Ne pas surcharger linstallation lectrique sassurer que lalimen-tation est correctement dimensionne et protge avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

Nutiliser que lanneau de levage pour lever lap-pareil. NE PAS utiliser le chariot, les bouteilles degaz ou tout autre accessoire.

Utiliser un engin de capacit adquate pour leverlappareil.

Si on utilise un chariot lvateur pour dplacer lunit, sassurer queles fourches sont suffisamment longues pour dpasser du ct op-pos de lappareil.

LEMPLOI EXCESSIF peut FAIRESURCHAUFFER LQUIPEMENT.

Prvoir une priode de refroidissement ; respec-ter le cycle opratoire nominal.

Rduire le courant ou le cycle opratoire avant dereprendre le soudage.

Ne pas obstruer les orifices ou filtrer lalimentation en air du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

Mettre un bracelet antistatique AVANT de mani-puler des cartes ou des pices.

Utiliser des pochettes et des botes antistatiquespour stocker, dplacer ou expdier des cartes decircuits imprims.

LES PICES MOBILES peuvent cau-ser des blessures.

Se tenir lcart des pices mobiles. Se tenir lcart des points de coincement tels

que les dvidoirs.

LES FILS DE SOUDAGE peuvent cau-ser des blessures.

Ne pas appuyer sur la gchette avant den avoirreu linstruction.

Ne pas diriger le pistolet vers soi, vers dautrespersonnes ou vers toute pice mcanique en en-gageant le fil de soudage.

LES ORGANES MOBILES peuventcauser des blessures.

Se tenir lcart des organes mobiles comme lesventilateurs.

Maintenir ferms et bien fixs les portes,panneaux, recouvrements et dispositifs de

protection.

LE RAYONNEMENT HAUTE FR-QUENCE (H. F.) risque de causer desinterfrences.

Le rayonnement haute frquence peut causerdes interfrences avec les quipements de radio-navigation et de communication, les services descurit et les ordinateurs.

Ne demander qu des personnes qualifies familiarises avec lesquipements lectroniques de faire fonctionner l installation.

Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences causes par linstallation.

Si la Federal Communications Commission signale des interfren-ces, arrter immdiatement lappareil.

Faire rgulirement contrler et entretenir linstallation. Maintenir soigneusement ferms les panneaux et les portes des sour-ces de haute frquence, maintenir le jeu dclatement au rglageadquat et utiliser une terre et un blindage pour rduire les interfren-ces ventuelles.

LE SOUDAGE LARC peut causerdes interfrences.

Lnergie lectromagntique peut causer desinterfrences avec lquipement lectroniquesensible tel que les ordinateurs et lquipementcommand par ordinateur tel que les robots.

Veiller ce que tout lquipement de la zone de soudage soit compati-ble au point de vue lectromagntique.

Pour rduire la possibilit dinterfrence, maintenir les cbles de sou-

dage aussi courts que possible, les grouper, et les poser aussi basque possible (par ex. : terre). Veiller souder une distance de 100 mtres de tout quipement

lectronique sensible. Veiller ce que le poste de soudage soit pos et mis la terre confor-

mment au prsent manuel. En cas dinterfrences aprs excution des directives prcdentes, il

incombe lutilisateur de prendre des mesures supplmentaires tel-les que le dplacement du poste, lutilisation de cbles blinds,luti lisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez dis-tance.

Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.

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2-4. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(tlphone : (305) 4439353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, norme American Welding Society AWSF4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL33126 (tlphone : (305) 4439353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire ProtectionAssociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA022699101 (tlphone : (617) 7703000, sites Web : www.nfpa.org etwww.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P1,de la Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (tlphone : (703) 4120900,site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca-nadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800)4636727 ou Toronto : (416) 7474044, site Web : www.csainterna-tional.org).

Practice For Occupational And Educational Eye And Face Protection,norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West42nd Street, New York, NY 100368002 (tlphone : (212) 6424900,site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, norme NFPA 51B, de la National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tl-phone : (617) 7703000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, de lU.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312)3532220, site Web : www.osha.gov).

2-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et les effets des champs magnti-ques basse frquence sur lorganisme

En parcourant les cbles de soudage, le courant cre des champs lec-tromagntiques. Les effets potentiels de tels champs restentproccupants. Cependant, aprs avoir examin plus de 500 tudes quiont t faites pendant une priode de recherche de 17 ans, un comitde spcialistes du National Research Council a conclu : Laccumula-tion de preuves na pas dmontr que lexposition aux champsmagntiques et aux champs lectriques haute frquence constitue unrisque pour la sant humaine . Toutefois, les tudes et lexamen despreuves se poursuivent. En attendant les conclusions finales de la re-cherche, il serait souhaitable de rduire lexposition aux champslectromagntiquespendant le soudage ou le coupage.

Afin de rduire les champs lectromagntiques en milieu de travail, res-pecter les consignes suivantes :

1. Garder les cbles ensemble en les torsadant ou en les fixant avec duruban adhsif.

2. Mettre tous les cbles du ct oppos loprateur.

3. Ne pas senrouler les cbles autour du corps.

4. Garder le poste de soudage et les cbles le plus loin possible de soi.

5. Placer la pince de masse le plus prs possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur mdecin. Si ce dernier les dclare aptes, il leur est recom-mand de respecter les consignes ci-dessus.

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SECTION 3 DEFINITIONS

3-1. Warning Label Definitions

Warning! Watch Out! There are possiblehazards as shown by the symbols.

1 Electric shock from welding electrodeor wiring can kill.

1.1 Wear dry insulating gloves. Do nottouch electrode with bare hand. Donot wear wet or damaged gloves.

1.2 Protect yourself from electric shockby insulating yourself from work andground.

1.3 Disconnect input plug or power beforeworking on machine.

2 Breathing welding fumes can behazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local

exhaust to remove the fumes.2.3 Use ventilating fan to remove fumes.3 Welding sparks can cause explosion

or fire.3.1 Keep flammables away from welding.

Do not weld near flammables.3.2 Welding sparks can cause fires. Have

a fire extinguisher nearby, and have awatchperson ready to use it.

3.3 Do not weld on drums or any closedcontainers.

4 Arc rays can burn eyes and injureskin.

4.1 Wear hat and safety glasses. Use earprotection and button shirt collar. Usewelding helmet with correct shade offilter. Wear complete body protection.

5 Become trained and read theinstructions before working on themachine or welding.

6 Do not remove or paint over (cover)the label.

1 1.1 1.2 1.3

2 2.1 2.2 2.3

3 3.1 3.2 3.3

4 4.1

5

6

S-179 310 A

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3-2. Torch/Cable Holder Label

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Electric shock from wiring cankill.

3 Do not operate unit or reachinside when torch/cableholder is removed.

4 Do not exceed 25 lb (12.4 kg)

maximum load on gun/cableholder or holder may break.

1 3

2

206 345 A

2

1

3-3. Weld Cable Connection Label

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Electric shock from weldingelectrode or wiring can kill.

3 Welding sparks or arcing fromunused electrode can causeexplosion or fire.

4 Do not connect more than oneelectrode cable to any singleweld output terminal.Disconnect cables for processnot in use. Have only onewelding circuit (process)connected at any given time

never two.

1 2 3

4

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3-4. Manufacturers Rating Label For CE Products

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3-5. Symbols And Definitions

Some symbols are found only on CE products.NOTE

AAmperes PanelLocal

Gas Tungsten ArcWelding (GTAW)

Shielded Metal ArcWelding (SMAW)

V Volts Do Not SwitchWhile Welding Arc Force (DIG) Spot Timer

Output Circuit Breaker Remote Temperature

Protective Earth(Ground) Alternating Current

High Frequency -Start Input

Postflow Timer Preflow TimerHigh Frequency -

Continuous 4T

4 Step Trigger Op-

eration Sequence

Gas (Supply) Gas Input Gas OutputIncrease/Decrease

Of Quantity

On Off Percent Direct Current

Balance Control Maximum CleaningMaximum

Penetration Electrode Positive

Electrode

Negative Crater Time Meter Single-Phase

U0 Rated No LoadVoltage (Average) U1 Primary Voltage U2 Conventional LoadVoltage Line Connection

I1 Primary Current I2 Rated WeldingCurrent X Duty Cycle 1 1Single-Phase

Combined AC/DCPower Source

IP Degree OfProtection I1eff Maximum EffectiveSupply Current I1max Rated MaximumSupply Current Hz Hertz

Electrode Work Thickness Gauge Spark Gap

S Seconds Final Current Start Time Start Amperage

Peak Time Spot SequenceStart/Crater Se-

quence Start Sequence

Crater Sequence Pulser Background Amps Pulse Frequency

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SECTION 4 INSTALLATION

OR

Location And Airflow

Falling Unit Can CauseInjury.

Use lifting eye to lift unit only,NOT running gear, gascylinders, or any otheraccessories.

Use equipment of adequatecapacity to lift and supportunit.

If using lift forks to move unit,be sure forks are long enoughto extend beyond oppositeside of unit.

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Rating Label

Use rating label to determine inputpower needs.

4 Line Disconnect Device

Locate unit near correct input pow-er supply.

Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

Be careful when placing ormoving unit over unevensurfaces.

4-1. Selecting A Location

1

2

Movement

Ref. ST-117 264-C / ST-801 971-A

4

1

3

18 in (460mm)

18 in (460mm)

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4-2. Dimensions And Weights

DimensionsA

BHeight

39-3/4 in (1010 mm) with retract-able lifting eye down

DC Width 22-1/2 in (572 mm)

Length 25 in (635 mm)

A 25 in (635 mm)

B 23-5/8 in (600 mm)

EFront C 1-3/8 in (35 mm)F

D 7/8 in (22 mm)

E 19-15/16 (506 mm)

F 22-1/4 (565 mm)

G 1/2 in (13 mm) Dia

WeightRef. ST-184 046G 4 Holes 526 lbs (239 kg)

4-3. Specifications

RatedAmperes Input at AC Balanced Rated Load Output,

50/60 Hz, Single-PhaseAmperage

RangeMaxOCV

WeldingOutput ** 200V 220V 230V 400V 440V 460V 520V 575V KVA KW

NEMA Class I(60) 300

NoPFC

1295*

1175*

1124*

653*

582*

562*

492*

452*

25.00.9*

14.30.4*

Amperes, 32Volts AC, 60%Duty Cycle

WithPFC

9869*

8963*

8560*

4935*

4431*

4330*

3726*

3424*

19.514.0*

14.00.4*

3 400A 80V

NEMA Class II(40) 350

NoPFC

1505*

1375*

1314*

753*

682*

662*

572*

532*

29.10.9*

17.70.4*

Amperes, 34Volts AC, 40%

Duty CycleWithPFC

11869*

10763*

10360*

5935*

5331*

5230*

4526*

4124*

23.714.0*

17.70.4*

3 400A 80V

*While idling**Power Factor Correction

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6 Minutes Welding 4 Minutes Resting4 Minutes Welding 6 Minutes Resting

4-4. Duty Cycle And Overheating

Duty Cycle is the percentage of 10minutes that the unit can weld atrated load without overheating.

If unit overheats, output stops, frontpanel voltmeter/ammeter displaysa HLP3 or HLP5 message (seeSection 6-4), and cooling fans run.Wait fifteen minutes for unit to cool.Reduce amperage or duty cycle be-fore welding.

Exceeding duty cycle candamage unit and void war-ranty.

40% Duty Cycle At 350 Amperes (60 Hz Models Only)

Overheating0

15

A

ORReduce Duty CycleMinutes

duty1 4/95 / SB-190 276

60% Duty Cycle At 300 Amperes

ssb1.1 10/91 ST-190 277 / ST-190 278

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

4-5. Volt-Ampere Curves

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4-6. 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 installedand grounded according to this manual. If interference still occurs, the user must take extra measures such as movingthe welding machine, using shielded cables, using line filters, or shielding the work area.

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Turn off power beforeconnecting to weld output

terminals.

WeldingAmperes

10 60%DutyCycle

60 100%DutyCycle

10 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

o no use worn,damaged, under-sized, or poorly

150 3 3 2 1 1/0 2/0 3/0 3/0

spliced cables.200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

ElectrodeWork 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

Ref. ST-801 972-C 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

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*Select weld cable size for pulsing application at peak amperage value.. S-0007-D

4-7. Remote 14 Receptacle

Socket* Socket Information

Turn off power before

A 24 volts dc.

connecting to receptacleB Contact closure to A completes 24 volts dc contactor control circuit.

C Command reference; 0 to +10 volts dc output to remote control.

D Remote control/feedback circuit common.

A J

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

BK I

C L N HK Chassis common.

D M GE F

F Current feedback, 1 volt per 100 amperes.

Ref. ST-801 972-CH Voltage feedback, 1 volt per 10 arc volts.

*The remaining sockets are not used.

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4-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle

Ref. ST-801 972-C / Ref. ST-801 973 / Ref. ST-157 858

Turn Off power before mak-ing connections.

1 Gas Valve In Fitting

Located on rear of unit.

2 Gas Valve Out Fitting

Fittings have 5/8-18 right-handthreads.

3 Cylinder Valve

Open valve slightly so gas flowblows dirt from valve. Close valve.

4 Regulator/Flow Gauge

Connect regulator/flow gauge togas cylinder.

Connect customer supplied gashose between regulator/flow gaugeand gas in fitting.

5 Flow Adjust

Typical flow rate is 20 cfh (cubic feetper hour).

6 115 V AC Receptacle

Receptacle is protected from over-load by circuit breaker CB1 (see

Section 6-2).

5

1

6

4

2

5/8, 3/4, 1-1/8 in

Tools Needed:

3

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4-9. Electrical Service Guide

All values calculated at 60% duty cycle.NOTE

Actual input voltage cannot exceed 10% of indicated required input voltageshown in both tables. If actual input voltage is outside of this range, damage to unitmay occur.

NOTE

50/60 Hertz Models Without Power Factor Correction

Input Voltage 200 220 230 400 440 460 520 575

Input Amperes At Rated Output 129 117 112 65 58 56 49 45

Max Recommended Standard Fuse OrCircuit Breaker Rating In Amperes 175 150 150 80 70 70 60 60

Min Input Conductor Size In AWG 4 4 4 8 8 8 8 10

Max Recommended Input ConductorLength In Feet (Meters)

111(34)

134(41)

146(45)

196(60)

238(72)

260(79)

332(101)

273(83)

Min Grounding Conductor Size In AWG 6 6 6 8 8 8 10 10

Reference: 1996 National Electrical Code (NEC) S-0092-J

50/60 Hertz Models With Power Factor Correction

Input Voltage 200 220 230 400 440 460 520 575

Input Amperes At Rated Output 98 89 85 49 44 43 37 34

Max Recommended Standard Fuse OrCircuit Breaker Rating In Amperes 150 125 125 70 70 60 60 50

Min Input Conductor Size In AWG 4 4 4 8 8 8 10 10

Max Recommended Input ConductorLength In Feet (Meters)

117(36)

141(43)

154(47)

204(62)

246(75)

269(82)

230(70)

281(86)

Min Grounding Conductor Size In AWG 6 6 6 8 8 10 10 10

Reference: 1996 National Electrical Code (NEC) S-0092-J

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1

4-10. Placing Jumper Links

Ref. ST-801 973-B

Disconnect and lockout/tag-out input power beforeinstalling or moving jumperlinks.

Check input voltage available atsite.

1 Jumper Link Label

Check label only one is on unit.

2 Jumper LinksMove jumper links to match inputvoltage.

Close access door, or go on toSection 4-11.

3/8 in

Tools Needed:

230 VOLTS 460 VOLTS200 VOLTS

L L L L L L

S-083 566-C2

230 VOLTS

L L

460 VOLTS

L L

S-010 587-B

575 VOLTS

L L

Do not overtightenjumper link nuts.

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SECTION 5 OPERATION5-1. Controls

A. For 200/230/460 Volts And Non CE Units

Ref. ST-183 200-A / Ref. ST-183 260-A / Ref. ST-801 972-C

Top row of lights in upper left corner areOn for SMAW. Bottom row are On forGTAW.

1 Process Control

See Section 5-3.

2 Current Control

See Section 5-4.

3 Output Control

See Section 5-5.

4 Start Mode Button

See Section 5-6.

5 Voltmeter

See Section 5-7

6 Ammeter

See Section 5-7

7 Amperage AdjustmentControl

See Section 5-8.

8 Output Selector Switch

See Section 5-2.

9 Power Switch Push Buttons

Use buttons to turn unit Off and On.

10 Postflow Time Control

See Section 5-11.

11 Preflow Time Control

See Section 5-10.

12 Balance/DIG Control

See Section 5-9.

Pulse Controls:13 Pulser On/Off Switch

See Section 5-12.

14 Background Amperage Control

See Section 5-12.

15 Pulses Frequency Control

See Section 5-12.

16 Peak Time Control

See Section 5-12.

17 Sequence Controls (Optional)

See Section 5-13.

8

1 2 3 4 5 6 7 13 14 15 16

10

11

12

17

9

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B. For CE Units

Ref. ST-191 372 / Ref. ST-191 371-A / Ref. ST-801 972-C

Top row of lights in upper left corner areOn for SMAW. Bottom row are On forGTAW.

1 Process Control

See Section 5-3.

2 Current Control

See Section 5-4.

3 Output Control

See Section 5-5.

4 Start Mode Button

See Section 5-6.

5 Voltmeter

See Section 5-7

6 Ammeter

See Section 5-7

7 Amperage AdjustmentControl

See Section 5-8.

8 Output Selector Switch

See Section 5-2.

9 Power Switch Push Buttons

Use buttons to turn unit Off and On.

10 Postflow Time Control

See Section 5-11.

11 Preflow Time Control

See Section 5-10.

12 Balance/DIG Control

See Section 5-9.

Pulse Controls:

13 Pulser On/Off SwitchSee Section 5-12.

14 Background Amperage Control

See Section 5-12.

15 Pulses Frequency Control

See Section 5-12.

16 Peak Time Control

See Section 5-12.

17 Sequence Controls (Optional)

See Section 5-13.

1 2 3 4 5 6 7 1314 15 16

10

11

12

9

8

17

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5-2. Output Selector Switch

Ref. ST-191 372

1 Output Selector Switch

Do not use AC output indamp areas, if movement isconfined, or if there is dan-ger of falling. Use AC outputONLY if required for thewelding process, and thenuse a remote control.

Do not change position of

switch while welding orwhile under load.

Use switch to select (DCEN) DirectCurrent Electrode Negative, AC, or(DCEP) Direct Current ElectrodePositive output without changingweld output cable connections.

NOTE: Changing position of Out-put Selector switch may alsochange Process control, Currentcontrol, Output control, and StartMode control settings to properlyfunction with latest Output Selectorswitch setting.

1

(CE Nameplate Shown)

5-3. Process Control

Ref. ST-191 372

1 Process Control

Use control to select Shielded Met-al Arc Welding (SMAW) or GasTungsten Arc Welding (GTAW) pro-cess.

For SMAW, press button to toggleLED to Stick position.

For GTAW, press button to toggleLED to TIG position.

NOTE:Lit LED indicates selectedmode.

When Output Selector switch posi-tion changes, LED may changeposition, based upon last selection.

11

(CE Nameplate Only)

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5-4. Current Control

1 Current Control

Use control to select front panel orremote current control.

For front panel current control,press button to toggle LED to Panelposition.

For remote current control, pressbutton to toggle LED to Remote 14position (see Section 4-7).

NOTE:Lit LED indicates selectedmode.

When Output Selector switch (seeSection 5-2) position changes, LEDmay change position, based uponlast selection.

11

(CE Nameplate Only)

5-5. Output Control

1 Output Control

Weld output terminals areenergized when power is On,and Output On LED is lit.

Use control to select front panel orremote output control.

For weld output, press button totoggle LED to On position.

For remote output control, pressbutton to toggle LED to Remote 14

position (see Section 4-7).NOTE:Lit LED indicates selectedmode.

When Output Selector switch (seeSection 5-2) position changes, Out-put control LED will always changeto Remote.

When Output On is selected, HFand gas control are disabled.

11

(CE Nameplate Only)

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5-6. Start Mode

1 Start Mode

For SMAW welding, press button to toggleLED to Off position.

For GTAW welding, use control to select Offfor no HF, Lift-Arc, HF for arc starting only,or continuous HF.

Application:

When Off is selected, use the scratch meth-

od to start an arc for both the SMAW andGTAW processes.

When Lift-Arc is selected, start arc asfollows:

2 TIG Electrode

3 Workpiece

Touch tungsten electrode to workpiece atweld start point, enable output with torchtrigger, foot control, or hand control. Holdelectrode to workpiece for 1-2 seconds,

and slowly lift electrode. An arc will formwhen electrode is lifted.

Shielding gas begins to flow when elec-trode touches work piece.

Normal open-circuit voltage is not presentbefore tungsten electrode touches work-piece; only a low sensing voltage is presentbetween electrode and workpiece. The sol-id state output contactor does not energizeuntil after electrode is touching workpiece.This allows electrode to touch workpiecewithout overheating, sticking, or gettingcontaminated.

Application:

Lift-Arc is used for the DCEN GTAW pro-cess when HF Start method is not per-mitted.

When HF Start is selected, start arc asfollows:

High frequency turns on to help start arcwhen output is enabled. High frequency

turns off when arc is started, and turns onwhenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTAWprocess is required.

When HF Continuous is selected, startarc as follows:

High frequency turns on when output is en-

ergized and remains on for duration of weld.Application:

HF Continuous is used when the AC GTAWprocess is required.

NOTE:Lit LED indicates selected mode.

When Output Selector switch positionchanges, LED may change position, basedupon last selection.

NOTE: Some start methods may not beavailable for all processes.

1

2

1 2SecondsTouch

Do NOT Strike Like A Match!

3

Lift-ArcStart Method

1

(CE Nameplate Only)

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5-7. Meters

1 Voltmeter

Voltmeter displays average voltage(to the nearest 0.1 V) at the weldoutput terminals.

2 Ammeter

Use meter to preset amperage. Me-ter displays average weld amper-age output of unit to nearest am-pere when welding.

1

2

5-8. Amperage Adjustment Control

1 Amperage Adjustment Control

Use control to adjust amperage,and preset amperage on ammeter(see Section 5-7). This control maybe adjusted while welding.

For remote amperage control,front panel control setting is themaximum amperage available. Forexample: If front panel control is setto 200 A, the range of the remoteamperage control is 3 to 200 A.

For pulse welding, use AmperageAdjust control to select from 3400amps of peak amperage (see Sec-tion 5-12).

For spot welding, use AmperageAdjust control to select from 3400amps of peak amperage (see Sec-tion 5-14).

1

(CE Nameplate Only)1

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5-9. Balance/DIG Control

1 Balance/DIG Control

Balance Control (AC GTAW):

Control changes the AC outputsquare wave. Rotating the controltowards 10 provides deeper pene-tration. Rotating the control towards0 provides more cleaning action ofthe workpiece.

When the control is in the Balancedposition, the wave shape providesequal penetration and cleaningaction.

Application:

When welding on oxide forming ma-terials such as aluminum or magne-sium, excess cleaning is not neces-sary. To produce a good weld, onlya minimal amount, approximately a0.10 in (2.5mm) of etched zonealong the weld toes is required.

Set control to 7 and adjust as nec-essary. Joint configuration, set-up,process variables, and oxide thick-ness may affect setting.

Arc rectification can occur whenwelding above 200 amps and/orwhile welding with helium gas. If thiscondition occurs, increasing theBalance control towards maximumpenetration, may help to restabilizethe arc.

DIG Control (AC And DC SMAW):

When set at 0, short-circuit amper-age at low arc voltage is the sameas normal welding amperage.

When setting is increased, short-circuit amperage at low arc voltageincreases.

Application:

Control helps arc starting or makingvertical or overhead welds by in-creasing amperage at low arc volt-age, and reduces electrode stickingwhile welding.

Ref. S-0795-A

Balanced3

10

0

More Penetration

More Cleaning

50% ElectrodePositive

50% ElectrodeNegative

32% ElectrodePositive

68% ElectrodeNegative

55% ElectrodePositive

45% ElectrodeNegative

Output Waveforms

Balance Control Examples

ArcSetting

11

(CE Nameplate Only)

5-10. Preflow Time Control

1 Preflow Time ControlUse control to set length of time thatgas flows (010 seconds) beforearc starts.

Application:

Preflow is used to purge the imme-diate weld area of atmosphere. Pre-flow also aids in consistent arcstarting.

11

(CE Nameplate Only)

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5-11. Postflow Time Control

1 Postflow Time Control

Use control to set length of time(050 seconds) gas flows afterwelding stops. It is important to setenough time to allow gas to flow un-til after the tungsten and weldpuddle has cooled down.

Application:

Postflow is required to cool tung-

sten and weld, and to prevent con-tamination of tungsten and weld. In-crease postflow time if tungsten orweld are dark in appearance.

1

(CE Nameplate Only)

1

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5-12. Setting Pulse Controls

1 On/Off Switch

Use switch to turn pulse functionOn and Off.

2 Background Amps

Use Background Amps control toset the low pulse of the weld am-perage, which cools the weldpuddle and affects overall heat in-put. Background Amps is set as a

percentage of peak amperage.3 Pulse Frequency

A range from 0.2510.0 pps(pulses per second). Control isused to determine appearance ofweld bead.

4 Peak Time

A range of 595% of each pulsecycle can be spent at the peakamperage level.

Peak amperage (3400 amps), isset with the Amperage Adjust-ment control (see Section A).Peak amperage is the highestwelding amperage allowed to oc-

cur in the pulse cycle. Weld pene-tration varies directly with peakamperage.

5 Pulsed Output Waveforms

Example shows affect changingthe Peak Time control has on thepulsed output waveform.

Application:

Pulsing refers to the alternatingraising and lowering of the weldoutput at a specific rate. Theraised portions of the weld outputare controlled in width, height,and frequency, forming pulses ofweld output. These pulses and

the lower amperage level be-tween them (called the back-ground amperage) alternatelyheat and cool the molten weldpuddle. The combined effectgives the operator better controlof penetration, bead width,crowning, undercutting, and heatinput. Controls can be adjustedwhile welding.

Pulsing can also be used for fillermaterial addition techniquetraining.

Peak Amp

Bkg AmpBalanced

More TimeAt PeakAmperage

More Time AtBackgroundAmperage

Pulsed Output WaveformsPercent (%) PeakTime Control Setting

(50%)

(80%)

(20%)

PPS

1

5

2 3 4

1 2 3 4

(CE Nameplate Only)

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5-13. Optional Sequence Controls

1 Sequence Selection Switch

See Section 5-14.

2 Start Time/Spot Time Control

See Section 5-15.

3 Start Current Control

See Section 5-15.

4 Crater Time Control

See Section 5-16.5 Final Current Control

See Section 5-16.

Ref. ST-191 372

42

1

35

421

35

(CE Nameplate Only)

5-14. Sequence Selection Switch

1 Sequence Selection Switch

Switch controls Off, Start, Cra-ter, Start/Crater, 4t, and Spotfunctions. Place switch in de-sired position.

Off Place switch in Off positionwhen Sequence Selection func-tions are not desired.

11

(CE Nameplate Only)

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5-15. Start Time/Spot Time Control And Start Current Control

1 Sequence Selection Switch

Place switch in Start position.

2 Start Time/Spot Time Control

Use control to select 015 secondsof start time.

3 Start Current Control

Use start control to select a startingcurrent (3400 amps) that is differ-

ent from the weld current. Note:Start current can be used with orwithout a remote control.

Application:

Start current can be used whileGTAW welding to assist in preheat-ing cold material prior to depositingfiller material, or to ensure a softstart. Start current can also be usedfor SMAW to ensure a more consis-tent arc strike.

2

3

11

2

3

(CE Nameplate Only)

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5-16. Crater Time Control And Final Current Control

1 Sequence Selection Switch

Place switch in Crater position.

2 Crater Time Control

Use control to reduce currentover a set period of time (015seconds) at the end of the weldcycle when NOT using a remotecurrent control.

3 Final Current Control

Final current is the current towhich weld current has slopeddown to (0100% of current set onAmperage Adjust control).

Application:

Crater Time should be used whileGTAW welding materials that arecrack sensitive, and/or the opera-tor wants to eliminate the crater atthe end of the weld.

Note: This applies if the operatoris using an on/off only type controlto start and stop the welding pro-cess.

2

1

3

(CE Nameplate Only)

1

3

2

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5-17. Start/Crater Sequence Controls

1 Sequence Selection Switch

Place switch in Start/Crater posi-tion.

2 Start Time/Spot TimeControl

Use control to select 015 sec-onds of start time.

3 Start Current Control

Use start control to select a start-ing current (3400 amps) that isdifferent from the weld current.

4 Crater Time Control

Use control to reduce currentover a set period of time (015seconds) at the end of the weldcycle when NOT using a remotecurrent control.

5 Final Current Control

Final current is the current towhich weld current has slopeddown to (0100% of current seton Amperage Adjust control).

Application:

Start current can be used whileGTAW welding to assist in pre-heating a cold material prior todepositing filler material. Startcurrent can also be used forSMAW to ensure a more consis-tent arc strike.

Crater Time can be used whileGTAW welding when material be-ing welded is crack sensitive, andthe operator is using an on/offtype control to start and stop thewelding process.

NOTE: Use this method whenthe function of a remote control isdesired, but only a remote on/off

control is available.

1

4

5

2

3

(CE Nameplate Only)

1

2

3

5

4

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5-18. 4T Sequence Selection Controls

1 Start Sequence Switch 4T Position

(Specific trigger method) Pressand hold torch trigger to startPreflow Time and arc at the StartCurrent level. The arc will remainat the Start Current level as longas the trigger is depressed. Re-lease trigger to change to mainweld current. To end main weldcurrent, press and hold trigger.Crater Time begins, and arcdrops to Final Current level andremains there until trigger is re-leased, at which time arc goesout, and Postflow Time begins.

While in 4T mode, there is a fea-ture available during the mainweld sequence that allows theoperator to toggle between weldcurrent and final current. Toswitch from weld current to finalcurrent, press and release torchtrigger within 3/4 of a second. Toreturn to weld current, press andrelease torch trigger within 3/4 ofa second again.

2 Start Time/Spot TimeControl

Use control to select 015 sec-onds of start time.

3 Start Current Control

Use start control to select a start-ing current (3400 amps) that isdifferent from the weld current.

4 Crater Time Control

Use control to reduce currentover a set period of time (015seconds) at the end of the weldcycle when not using a remotecontrol.

5 Final Current ControlFinal current is the current towhich weld current has slopedup/down to (0100% of currentset on Amperage Adjust con-trol).

Application:

Use 4T trigger method when thefunctions of a remote currentcontrol are desired, but only a re-mote on/off control is available.

1

2

3

4

5

2

3

5

4

1

(CE Nameplate Only)

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5-19. Spot Time Control

1 Sequence Selection Switch Spot Position

Used with the (GTAW) TIG Spotprocess, generally with a direct cur-rent electrode negative (DCEN) set-up.

2 Start Time/Spot Time Control

Use control to select 015 secondsof spot time.

Use Amperage Adjust control (seeSection 5-8) to set amperage.

Application:

TIG spot welding is used for joiningthinner materials that are in closecontact, with the fusion method. Agood example would be joining coilends.

1

22

1

(CE Nameplate Only)

5-20. Timer/Cycle Counter

1 Current Control

2 Output (Contactor) Control

To read timer/cycle counter, holdCurrent and Output (contactor) but-tons while turning on power.

3 Timer Display

The hours and minutes are dis-played on the volt and amp metersfor the first five seconds, and areread as 1, 234 hours and 56 min-utes.

4 Cycle Display

The cycles are displayed on the voltand amp meters for the next fiveseconds, and are read as 123, 456cycles.

1 2

(CE Nameplate Only)

1 2 3

4 5 6

1 2 3

4 5 6

3

4

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SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

Disconnect power before maintaining.

3 Months

ReplaceUnreadable

Labels

Clean AndTightenWeld

Terminals

Repair OrReplaceCracked

WeldCables

Adjust SparkGaps

ReplaceCracked

Parts

14-Pin Cord Gas Hose Torch Cable

6 Months

Blow Out Or Vacuum Inside,During Heavy Service, Clean Monthly

OR Warranty is void if machine fails

due to contaminates inside.

6-2. Circuit Breaker CB1

Ref. ST-801 972-C

Turn off power before reset-ting breaker.

1 Circuit Breaker CB1

If CB1 opens, high frequency andoutput to the 115 volts ac duplex re-ceptacle stop. Press button to resetbreaker.

1

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6-3. Adjusting Spark Gaps

Ref. ST-801 972-C

Turn off welding powersource and disconnect andlockout/tagout input powerbefore adjusting spark gaps.

Open access door.

1 Tungsten End Of Point

Replace point if tungsten end dis-appears; do not clean or dresstungsten.

2 Spark Gap

Normal spark gap is 0.012 in (0.305mm).

If adjustment is needed, proceed asfollows:

3 Adjustment Screws

Loosen screws. Place gauge ofproper thickness in spark gap.

4 Pressure Point

Apply slight pressure at point untilgauge is held firmly in gap. Tightenscrews to 12 in/lbs torque (overtigh-tening will deform plastic base). Ad-

just other gap.

Reinstall access door.

Tools Needed:

5/32 in

0.012 in (0.305 mm)

1

4

3

4

3

2

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6-4. Voltmeter/Ammeter Help Displays

All directions are in reference to the frontof the unit. All circuitry referred to is lo-cated inside the unit.

0 Help 0 Display

Indicates a short in the thermal protection cir-cuitry located on the transformer of the unit.If this display is shown, contact a Factory Au-thorized Service Agent.

1 Help 1 Display

Not used.2 Help 2 Display

Indicates a malfunction in the thermalprotection circuitry located on the transform-er of the unit. If this display is shown, contacta Factory Authorized Service Agent.3 Help 3 Display

Indicates the transformer of the unit has

overheated. The unit has shut down to allowthe fan to cool it (see Section 4-4). Operationwill continue when the unit has cooled.

4 Help 4 Display

Indicates a malfunction in the thermalprotection circuitry located on the rectifierassembly of the unit. If this display is shown,contact a Factory Authorized Service Agent.

5 Help 5 DisplayIndicates the rectifier assembly of the unithas overheated. The unit has shut down toallow the fan to cool it (see Section 4-4). Op-eration will continue when the unit hascooled.

6 Help 6 Display

Not used.

7 Help 7 Display

Not used.

8 Help 8 Display

Not used.

9 Help 9 Display

Indicates a short in the thermal protection cir-cuitry located on the rectifier assembly of theunit. If this display is shown, contact a Facto-

ry Authorized Service Agent.10 Help 10 Display

Indicates Remote Output control is acti-vated. Release Remote Output control toclear help message.

11 Help 11 Display

Indicates Output Selector switch is not incorrect position (see Section 5-2).

A

V

A

V 3

A

V

HLP

1

HLP

2

HLP

3A

V

HLP

4A

V

HLP

5

A

V

HLP

6

A

V

HLP

7A

V

HLP

8

6 8

2 5

7

1 4

A

V

HLP

9

9

A

V

HLP

10

10

A

V

HLP

11

11

A

V

HLP

0

0

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6-5. Troubleshooting

NOTE:The remedies listed below are recommendations only. If these remedies do not fixthe trouble with your unit, have a Factory Authorized Service Agent check unit.There are not user serviceable parts inside unit.

Refer to Section 6-4 for any Help (HLP) message displayed on voltmeter/ammeter.

Trouble Remedy

No weld output; unit completely Place line disconnect switch in On position (see Section 4-11).inoperative.

Check and replace line fuse(s), if necessary (see Section 4-11).

Check for proper input power connections (see Section 4-11).

Check for proper jumper link position (see Section 4-10).

No weld output; unit on. If using remote control, place Output control in Remote 14 position, and make sure remote control isconnected to Remote 14 receptacle. If remote is not being used, place Output control in On position(see Section 5-1).

Check, repair, or replace remote control.

Have Factory Authorized Service Agent check unit.

Unit provides only maximum or

Make sure Amperage control is in proper position (see Section 5-1).minimum weld output.

Have Factory Authorized Service Agent check unit.

Erratic or improper weld output. Use proper size and type of weld cabl