Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Arc Welding Power Source

OM-358 188 291BDecember 1998

Dynasty 300 DX

230/460 Volt Models W/Autolink

400 Volt Models

And Non-CE Models

Visit our website at

www.Miller-Welds.com

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor call 1-800-4-A-Miller.

Thank you and congratulations on choosing Miller. Nowyou can get the job done and get it done right. We knowyou dont have time to do it any other way.

Thats why when Niels Miller first started building arcwelders in 1929, he made sure his products offeredlong-lasting value and superior quality. Like you, hiscustomers couldnt afford anything less. Miller productshad to be more than the best they could be. They had tobe the best you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. They willhelp 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 reliableservice with proper maintenance. And if forsome reason the unit needs repair, theres aTroubleshooting section that will help youfigure out what the problem is. The parts listwill then help you to decide which exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registeredto the ISO 9001 QualitySystem Standard.

Working as hard as youdo every power sourcefrom Miller is backed bythe most hassle-free war-ranty in the business.

From Miller to You

Miller offers a TechnicalManual which providesmore detailed service andparts information for yourunit. To obtain a TechnicalManual, contact your localdistributor. Your distributorcan also supply you withWelding Process Manualssuch as SMAW, GTAW,GMAW, and GMAW-P.

The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAW

TABLE OF CONTENTSSECTION 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. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 71-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 DEFINITIONS (CE Models) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Manufacturers Rating Label For CE Products 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 INSTALLATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Volt-Ampere Curves 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle and Overheating 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Selecting a Location 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. 115 Volts AC Duplex Receptacle, Circuit Breaker CB1 (Optional), And Power Switch 16. . . . . 3-6. Weld Output Terminals and Selecting Cable Sizes 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Remote 14 Receptacle Information 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Remote Program Select Inputs (Optional For Non CE Models) 18. . . . . . . . . . . . . . . . . . . . . . . . 3-9. Gas Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10.Electrical Service Guide 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11.Connecting Input Power 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 OPERATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Description Of Controls (Use With Sections A And B) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Remote Trigger (Normal) Mode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Remote Trigger (2T) Hold Mode 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. 4T (Specific Trigger Method) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Reconfiguring 4T For Mini Logic Control, Spot, Or Contactor On Lift-Arc 27. . . . . . . . . . . . . . . . 4-7. Mini Logic Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Spot Control Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Contactor On Lift-Arc Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10.Lift-Arc And HF TIG Start Procedures 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11.Programmable HF Start Amperage And Time Modes 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12.Arc Timer/Counter Display 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13.Lock Out Functions 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 MAINTENANCE AND TROUBLESHOOTING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Blowing Out Inside of Unit 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Voltmeter/Ammeter Help Displays 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 ELECTRICAL DIAGRAM 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 HIGH FREQUENCY 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Welding Processes Requiring High Frequency 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Incorrect Installation 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Correct Installation 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 SELECTING AND PREPARINGTUNGSTEN ELECTRODE 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 GUIDELINES FOR TIG WELDING (GTAW) 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Positioning The Torch 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Torch Movement During Welding 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Positioning Torch Tungsten For Various Weld Joints 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 PARTS LIST 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIESWARRANTY

OM-358B

WARNINGThis product, when usedfor welding or cutting,produces fumes orgases which containchemicals known to theState of California tocause birth defects and,in some cases, cancer.(California Health &Safety Code Section25249.5 et seq.)

dec_con1 10/95

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: Dynasty 300 DXconforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

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

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

Standards

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

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1(December 1996 Draft revision)

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989Insulation 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. Luigi Vacchini, Managing DirectorMILLER Europe S.P.A.Via Privata Iseo20098 San GiulianoMilanese, Italy

Telephone: 39(02)98290-1Fax: 39(02)98281-552

OM-358 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_5/97

1-1. Symbol UsageMeans 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 to

call 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 NO TAG. Read and fol-low all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair 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 mats

or 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 on

unit. Disconnect input power or stop engine before installing or

servicing 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 inputpower 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 use work clamp or work cable.

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

Use only well-maintained equipment. Repair or replace 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 prevent

contact with any metal object. Do not connect more than one electrode or work cable to any

single 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 remove

welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the

manufacturers 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.

OM-358 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 explo-sion.

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. If

this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can

easily 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 can

cause 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, heavy

shirt, 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 grinding

cause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with sideshields 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 or

torch.

MAGNETIC FIELDS can affect pacemak-ers.

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 is

high.

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 in

use or connected for use. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in SafetyStandards.

OM-358 Page 3

1-3. Additional Symbols for Installation, Operation, and MaintenanceFIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near

combustible 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 running

gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and

support unit. If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before

starting to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling

boards or parts. Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury. Keep away from moving parts. Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury. Do not press gun trigger until instructed to do

so.

Do not point gun toward any part of the body,other people, or any metal when 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, andcommunications 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, keep

spark 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 iselectromagnetically 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. Principal Safety StandardsSafety in Welding and Cutting, ANSI Standard Z49.1, from AmericanWelding Society, 550 N.W. LeJeune Rd, Miami FL 33126Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-dent of Documents, U.S. Government Printing Office, Washington, D.C.20402.Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, AmericanWelding Society Standard AWS F4.1, from American Welding Society,550 N.W. LeJeune Rd, Miami, FL 33126National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3.Safe Practices For Occupation And Educational Eye And FaceProtection, ANSI Standard Z87.1, from American National StandardsInstitute, 1430 Broadway, New York, NY 10018.Cutting And Welding Processes, NFPA Standard 51B, from NationalFire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-358 Page 4

1-5. EMF InformationConsiderations 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.

OM-358 Page 5

SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATIONsom _nd_Fre 4/97

1-1. Signification des symbolesSignifie Mise en garde ! Soyez vigilant ! Cette procdureprsente des risques de danger ! Ceux-ci sont identifispar des symboles adjacents aux directives.

Identifie un message de scurit particulier.

Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a desrisques de danger relis aux CHOCS LECTRIQUES, aux PICES ENMOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboleset aux directives ci-dessous afin de connatre les mesures prendre pourviter tout danger.

1-2. Dangers relatifs au soudage larc Les symboles prsents ci-aprs sont utiliss tout au long du

prsent manuel pour attirer votre attention et identifier les risquesde danger. Lorsque vous voyez un symbole, soyez vigilant etsuivez les directives mentionnes afin dviter tout danger. Lesconsignes de scurit prsentes ci-aprs ne font que rsumerlinformation contenue dans les normes de scurit numres la section 1-5. Veuillez lire et respecter toutes ces normes descurit.

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

Au cours de lutilisation, tenir toute personne lcart et plus par-ticulirement les enfants.

UN CHOC LECTRIQUE peut tuer.Un simple contact avec des pices lectriques peutprovoquer une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tensionds que lappareil est sur ON. Le circuit dentre et lescircuits internes de lappareil sont galement sous

tension ce moment-l. En soudage semi-automatique ou automatique,le fil, le dvidoir, le logement des galets dentranement et les picesmtalliques en contact avec le fil de soudage sont sous tension. Desmatriels mal installs ou mal mis la terre prsentent un danger. Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant

pas de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres

moyens isolants suffisamment grands pour empcher le contact phy-sique ventuel avec la pice ou la terre.

Ne pas se servir de source lectrique courant lectrique dans les zoneshumides, dans les endroits confins ou l o on risque de tomber.

Se servir dune source lectrique courant lectrique UNIQUEMENT si leprocd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savre nces-saire, se servir 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. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

Installer et mettre la terre correctement cet appareil 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.

En effectuant les raccordements dentre fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

Vrifier frquemment le cordon dalimentation pour voir sil nest pasendommag ou dnud remplacer le cordon immdiatement sil estendommag un cble dnud peut provoquer une lectrocution.

Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

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

cble distinct ne pas utiliser le connecteur de pice ou le cble deretour.

Ne pas toucher llectrode quand on est en contact avec la pice, laterre ou une lectrode provenant dune autre machine.

Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce 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-mtalavec la pice souder ou la table de travail, le plus prs possible de lasoudure.

Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

Il y a DU COURANT CONTINU IMPORTANT dans lesconvertisseurs aprs la suppression de lalimenta-tion lectrique. Arrter les convertisseurs, dbrancher le courant lectrique, et d-

charger les condensateurs dalimentation selon les instructionsindiques dans la partie entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

Eloigner votre tte des fumes. Ne pas respirerles fumes.

A lintrieur, ventiler la zone et/ou utiliser un chappement au niveaude larc pour lvacuation des fumes et des gaz de soudage.

Si la ventilation est insuffisante, utiliser un respirateur alimenta-tion dair homologu.

Lire les spcifications de scurit des matriaux (MSDSs) et lesinstructions du fabricant concernant les mtaux, les consomma-bles, les revtements, les nettoyants et les dgraisseurs.

Travailler dans un espace ferm seulement sil est bien ventil ou enportant un respirateur alimentation dair. Demander toujours unsurveillant dment form de se tenir proximit. Des fumes et desgaz de soudage peuvent dplacer lair et abaisser le niveau doxy-gne provoquant des blessures ou des accidents mortels. Sassu-rer que lair de respiration ne prsente aucun danger.

Ne pas souder dans des endroits situs proximit doprations dedgraissage, de nettoyage ou de pulvrisation. La chaleur et lesrayons de larc peuvent ragir en prsence de vapeurs et former desgaz hautement toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soit bienventil, et si ncessaire, en portant un respirateur alimentationdair. Les revtements et tous les mtaux renfermant ces lmentspeuvent dgager des fumes toxiques en cas de soudage.

LES FUMES ET LES GAZ peuventtre dangereux.

OM-358 Page 6

Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer

des brlures dans les yeux et sur la peau. Des tincelles sont projetespendant le soudage.

LES RAYONS DE LARC peuvent pro-voquer des brlures dans les yeux etsur la peau.

Porter un casque de soudage muni dun cran de filtre appropri pourprotger votre visage et vos yeux pendant le soudage ou pour regar-der (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).

Porter des protections approuvs pour les oreilles si le niveau sondre esttrop lev.

Utiliser des crans ou des barrires pour protger des tiers de lclairet de lblouissement; demander aux autres personnes de ne pas re-garder larc.

Porter des vtements de protection constitu dans une matire dura-ble, rsistant au feu (cuir ou laine) et une protection des pieds.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent treprojetes de larc de soudure. La projection dtincel-

les, des pices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avec desobjets mtalliques peut provoquer des tincelles, une explosion, unsurchauffement ou un incendie. Avant de commencer le soudage, vrifieret sassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

Se protger et dautres personnes de la projection dtincelles et demtal chaud.

Ne pas souder dans un endroit l o des tincelles peuvent tomber surdes substances inflammables.

Dplacer toutes les substances inflammables une distance de 10,7m de larc de soudage. En cas dimpossibilit les recouvrir soigneuse-ment avec des protections homologus.

Des tincelles et des matriaux chauds du soudage peuvent facile-ment passer dans dautres zones en traversant de petites fissures etdes ouvertures.

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

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

Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-rs correctement conformment AWS F4.1 (voir les normes descurit).

Brancher le cble sur la pice le plus prs possible de la zone de sou-dage pour viter le transport du courant sur une longue distance pardes chemins inconnus ventuels en provoquant des risques dlec-trocution et dincendie.

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 la pointe de contact.

Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sans re-vers, des chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos pochestelles quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTESpeuvent blesser les yeux. Le soudage, lcaillement, le passage de la pice

la brosse en fil de fer, et le meulage gnrentdes tincelles et des particules mtalliques vo-

lantes. Pendant la priode de refroidissement des soudures, elles ris-quent de projeter du laitier. Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort. Fermer lalimentation du gaz protecteur en cas de

non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respi-

rateur dadduction dair homologu.

DES PICES CHAUDES peuvent pro-voquer des brlures graves. Ne pas toucher des parties chaudes mains nues Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sapprocherdes oprations de soudage larc, de gougeage oude soudage par points.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecterloue.

Porter des protections approuvs pour les oreilles sile niveau sondre est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles de gazfont normalement partie du procd de soudage, les

manipuler avec prcaution.

Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, du laitier, des flammes ouvertes, des tin-celles et des arcs.

Placer les bouteilles debout en les fixant dans un support stationnai-re ou dans un porte-bouteilles pour les empcher de tomber ou dese renverser.

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

Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une

bouteille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifique;les maintenir ainsi que les lments associs en bon tat.

Ne pas tenir la tte en face de la sortie en ouvrant la soupape de labouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas duti-lisation ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz com-prim, les quipements associs et les publications P-1 CGA nu-mres dans les normes de scurit.

Si des BOUTEILLES sont endomma-ges, elles pourront exploser.

OM-358 Page 7

1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnementet la maintenance

Risque DINCENDIE OUDEXPLOSION. Ne pas placer lappareil sur, au-dessus ou proxi-

mit de surfaces infllammables. Ne pas installer lappareil proximit de produits inflammables Ne pas surcharger linstallation lectrique sassurer que lalimen-

tation est correctement dimensionn et protg avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

Utiliser lanneau de levage uniquement pour sou-lever lappareil, NON PAS les chariot, les bouteil-les de gaz ou tout autre accessoire.

Utiliser un engin dune capacit approprie poursoulever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassurerque les fourches sont suffisamment longues pour dpasser du ctoppos de lappareil.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT. Prvoir une priode de refroidissement, respec-

ter le cycle opratoire nominal. Rduire le courant ou le cycle opratoire avant de

recommancer le soudage. Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims. tablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistatiques

pour stocker, dplacer ou expdier des cartes decircuits imprimes.

DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent pro-voquer des blessures. Ne pas appuyer sur la gachette avant den avoir

reu linstruction. Ne pas diriger le pistolet vers soi, dautres person-

nes ou toute pice mcanique en engageant le filde soudage.

DES ORGANES MOBILES peuventprovoquer des blessures. Rester lcart des organes mobiles comme le

ventilateur. Maintenir ferms et fixement en place les portes,

panneaux, recouvrements et dispositifs deprotection.

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences. Le rayonnement haute frequence peut provoquer

des interfrences avec les quipements de ra-dionavigation et de communication, les servicesde scurit et les ordinateurs.

Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-tion.

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

Si le FCC signale des interfrences, arrter immdiatement lappa-reil.

Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distancecorrecte et utiliser une terre et et un blindage pour rduire les interf-rences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences. Lnergie lectromagntique risque de provoquer

des interfrences pour 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 com-patible lectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poser aussibas que possible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipementlectronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcdentes, ilincombe 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 doiventdabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.

OM-358 Page 8

1-4. Principales normes de scuritSafety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Wel-ding Society, 550 N.W. Lejeune Rd, Miami FL 33126Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402.Recommended Safe Practice for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, norme AWSF4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL33126National Electrical Code, NFPA Standard 70, de la National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de la Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.Rgles de scurit en soudage, coupage et procds connexes, normeCSA W117.2, de lAssociation canadienne de normalisation, vente denormes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.Safe Practices For Occupation And Educational Eye And Face Protec-tion, norme ANSI Z87.1, de lAmerican National Standards Institute,1430 Broadway, New York, NY 10018.Cutting and Welding Processes, norme NFPA 51B, de la National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs lectromagntiquesDonnes sur le soudage lectrique et sur les effets, pour lorganisme,des champs magntiques basse frquenceLextrait suivant est tir des conclusions gnrales du document intitulBiological Effects of Power Frequency Electric & Magnetic Fields Background Paper, OTABPE53 (Washington DC : U.S. Govern-ment Printing Office, mai 1989), publi par le Office of TechnologyAssessment du Congrs amricain : ... il existe maintenant dabon-dantes donnes scientifiques compiles la suite dexpriences sur lacellule ou dtudes sur des animaux et des humains, qui montrent clai-rement que les champs lectromagntiques basse frquence peuventavoir des effets sur lorganisme et mme y produire des transforma-tions. Mme sil sagit de travaux de trs grande qualit, les rsultatssont complexes. Cette dmarche scientifique ne nous permet pasdtablir un tableau densemble cohrent. Pire encore, elle ne nous per-met pas de tirer des conclusions finales concernant les risquesventuels, ni doffrir des conseils sur les mesures prendre pour rdui-re sinon liminer les risques ventuels. (Traduction libre)

Afin de rduire les champs lectromagntiques dans lenvironnementde travail, respecter les consignes suivantes :1 Garder les cbles ensembles en les torsadant ou en les

attachant avec du ruban adhsif.2 Mettre tous les cbles du ct oppos de loprateur.3 Ne pas courber pas et ne pas entourer pas les cbles autour de

vous.

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

5 Relier la pince de masse le plus prs possible de la zone desoudure.

Consignes relatives aux stimulateurs cardiaques :Les consignes mentionnes prcdemment font partie de celles desti-nes aux personnes ayant recours un stimulateur cardiaque. Veuillezconsulter votre mdecin pour obtenir plus de dtails.

OM-358 Page 9

SECTION 2 DEFINITIONS (CE Models)2-1. Warning Label Definitions

Warning! Watch Out! There arepossible hazards as shown by thesymbols.1 Electric shock from welding

electrode or wiring can kill.1.1 Wear dry insulating gloves.

Do not touch electrode withbare hand. Do not wear wet ordamaged gloves.

1.2 Protect yourself from electricshock by insulating yourselffrom work and ground.

1.3 Disconnect input plug orpower before working onmachine.

2 Breathing welding fumes canbe hazardous to your health.

2.1 Keep your head out of thefumes.

2.2 Use forced ventilation or localexhaust to remove the fumes.

2.3 Use ventilating fan to removefumes.

3 Welding sparks can causeexplosion or fire.

3.1 Keep flammables away fromwelding. Do not weld nearflammables.

3.2 Welding sparks can causefires. Have a fire extinguishernearby, and have awatchperson ready to use it.

3.3 Do not weld on drums or anyclosed containers.

4 Arc rays can burn eyes andinjure skin.

4.1 Wear hat and safety glasses.Use ear protection and buttonshirt collar. Use weldinghelmet with correct shade offilter. Wear complete bodyprotection.

5 Become trained and read theinstructions before working onthe machine or welding.

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

1/96

1 1.1 1.2 1.3

3 3.1 3.2 3.3

4 4.1

+

2 2.1 2.2

+

+

5 6

+

2.3

S-179 310

OM-358 Page 10

Warning! Watch Out! There arepossible hazards as shown by thesymbols.1 Electric shock from wiring can

kill.2 Disconnect input plug or

power before working onmachine.

3 Hazardous voltage remainson input capacitors afterpower is turned off. Do nottouch fully chargedcapacitors.

4 Always wait 60 seconds afterpower is turned off beforeworking on unit, OR

5 Check input capacitor voltage,and be sure it is near 0 beforetouching any parts.

6 When power is applied failedparts can explode or causeother parts to explode.

7 Flying pieces of parts cancause injury. Always wear aface shield when servicingunit.

8 Always wear long sleeves andbutton your collar whenservicing unit.

9 After taking properprecautions as shown,connect power to unit.

S-185 836

> 60 s

VV

V

1 2 3 4 5

6 7 8 9

S-179 309-A

=

OM-358 Page 11

2-2. Manufacturers Rating Label For CE Products

ST-189 968-A

For label locationsee Section 3-4.

OM-358 Page 12

2-3. Symbols And Definitions

A Amperes PanelLocal Gas Tungsten ArcWelding (GTAW) Shielded Metal ArcWelding (SMAW)V Volts Input 3 Phase Static FrequencyConverter-Transformer-Rectifier

Output Circuit Breaker Remote Touch Start(GTAW)

Protective Earth(Ground) Postflow Timer Preflow Timer S Seconds

On Off Positive Negative

AlternatingCurrent Gas Input Gas Output I2 Rated WeldingCurrent

X Duty Cycle Direct Current Line Connection U2 Conventional LoadVoltage

U1 Primary Voltage IP Degree OfProtection I1max Rated MaximumSupply Current I1eff Maximum EffectiveSupply Current

U0 Rated No LoadVoltage (Average) Pulse BackgroundAmperage Initial Amperage Increase/DecreaseOf QuantityNormal Trigger Op-

eration (GTAW)Two-Step Trigger

Operation (GTAW)Four-Step TriggerOperation (GTAW) Percent

Hz Hertz Recall FromMemory Arc Force (DIG) Impulse Starting(GTAW)Final Slope Final Amperage Pulse PercentOn Time Initial Slope

Contactor Control(Stick) Pulser On-Off

TIG Weld AmpsAnd Peak Amps

While PulsingPulse Frequency

Work Electrode Balance % ENTime (AC GTAW)

Unit may be usedin environmentswith increased

hazard of electricshock

OM-358 Page 13

SECTION 3 INSTALLATION

3-1. Specifications

A. For Multivoltage Units

AmperageRange

MaximumOpen-Circuit

Amperes Input at Rated Load Output 60 Hz

Input Power Rated Welding OutputAmperage

Range Open-CircuitVoltage DC 230 V 460 V KVA KW

Three Phase

250 A @ 30 Volts AC, 40%Duty Cycle

5300 95

26.3*.27

17.9*.15

14.2*.09

10.5*.04

Three Phase200 A @ 28 Volts DC, 40%

Duty Cycle

5300 95 20.5*.27

13.4*.15

8.4*.09

7.6*.04

Single Phase

250 A @ 30 Volts AC, 40%Duty Cycle

5300 95

62.6*.33

32.2*.18

14.8*.10

10.4*.07

Single Phase200 A @ 28 Volts DC, 40%

Duty Cycle

5300 9544

*.3325.8*.18

11.9*.1

8.1*.07

*While idling

B. For Single Voltage Units

Rated Welding Output Amperage Range

MaximumOpen-CircuitVoltage DC

Amperes Input At RatedOutput, 50Hz - Three-Phase

400 V KVA KW250 A @ 30 VAC,40% Duty Cycle

5 300 95 VDC 20.2 (0.13*) 14.0 (0.09*) 10.5 (0.04*)

200 A @ 28 VDC,40% Duty Cycle

5 300 95 VDC 15.1 (0.13*) 10.5 (0.09*) 7.5 (0.04*)

*While idling

3-2. Volt-Ampere Curves

SA-185 793 / SA-186 294

Volt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofunit. Curves of other settings fall be-tween curves shown.

OM-358 Page 14

3-3. Duty Cycle and Overheating

4 Minutes Welding 6 Minutes Resting

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.If unit overheats, output stops, aHelp message is displayed (seeSection 5-3), and cooling fan runs.Wait fifteen minutes for unit to cool.Reduce amperage or voltage, orduty cycle before welding. Exceeding duty cycle can

damage unit and voidwarranty.

250 A @ 40% Duty Cycle For AC

Overheating0

15

A or V

ORReduce Duty CycleMinutes

sduty1 5/95 / SA-185 794

200 A @ 40% Duty Cycle For DC

OM-358 Page 15

3-4. Selecting a Location

loc_2 3/96 - ST-802 135-A

1 Lifting HandlesUse handles to lift unit.2 Hand CartUse cart or similar device to moveunit.3 Rating Label (Non CE

Models)Use rating label to determine inputpower needs.4 Plate Label (CE Models)5 Line Disconnect DeviceLocate unit near correct inputpower supply. Special installation may be

required where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

24 in(610 mm)

17 in(432 mm)

12-1/2 in(318 mm)

Movement Do not move or operate unit

where it could tip.

Location And Airflow

5

3

Dimensions And Weight

18 in(460 mm)

18 in(460 mm)

90 lb (40.7 kg) 110 lb (50kg) w/aux power

21

1

4

OM-358 Page 16

3-5. 115 Volts AC Duplex Receptacle, Circuit Breaker CB1 (Optional), And Power Switch

ST-801 866-A

1 AC Duplex Receptacle115 V 10 A for 230/460 volt models.115 V 7 A for 400 volt models.2 Circuit Breaker CB1CB1 protects duplex receptaclefrom overload.Press button to reset breaker.3 Power On/Off Switch

13

2

3-6. Weld Output Terminals and Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less 150 ft(45 m)200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Weld OutputTerminals

WeldingAmperes

10 60%DutyCycle

60 100%Duty Cycle 10 100% Duty Cycle

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

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

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

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

*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. Contact yourdistributor for the mm2 equivalent weld cable sizes.**Select weld cable size for pulsing application at peak amperage value.NOTE: For proper installation of gas hose, the use of a quick connect torch (such as Weldcraft QWP-17 or QWP-20), is recommenced.

S-0007E

OM-358 Page 17

3-7. Remote 14 Receptacle Information

ST-802 135-ASocket* Socket Information

ST-802 135-A

A JB K I

24 VOLTS DC

A Contactor control, 24 volts dc.

A JB K I

C L N HD M G

E F

24 VOLTS DCB Contact closure to A completes 24 volts dc

contactor control circuit, and enables output.

E F

REMOTE

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

REMOTEOUTPUT

CONTROLD Remote control circuit common.

CONTROLE 0 to +10 volts dc input command signal from

remote control.

A/VAMPERAGE

F Current feedback; +1 volt dc per 100 amperes.A/V

AMPERAGEVOLTAGE H Voltage feedback; +1 volt dc per 10 outputreceptacle volts.

GND K Chassis common.

*The remaining sockets are not used.

OM-358 Page 18

3-8. Remote Program Select Inputs (Optional For Non CE Models)10-Pin Receptacle RC2

Pin Designations

0=No Connection

1=Connected To Ground (Pin G)

Function C H F E D

No Remote Control 0 0 0 X X

Stick EP Of Current Program 1 0 0 X X

Stick AC Of Current Program 1 1 0 x x

TIG AC Of Current Program 0 1 0 x x

Program 1 Stick EP 1 0 1 0 0

Program 2 Stick EP 1 0 1 0 1

Program 3 Stick EP 1 0 1 1 0

Program 4 Stick EP 1 0 1 1 1

Program 1 TIG EN 0 0 1 0 0

Program 2 TIG EN 0 0 1 0 1

Program 3 TIG EN 0 0 1 1 0

A JBH

GProgram 4 TIG EN 0 0 1 1 1JB

ICGF Program 1 Stick AC 1 1 1 0 0IC

D EF

Program 2 Stick AC 1 1 1 0 1

Program 3 Stick AC 1 1 1 1 0

ST-802 135-A

*The remaining sockets are not used.Program 4 Stick AC 1 1 1 1 1

*The remaining sockets are not used.Program 1 TIG AC 0 1 1 0 0

Program 2 TIG AC 0 1 1 0 1

Program 3 TIG AC 0 1 1 1 0

Program 4 TIG AC 0 1 1 1 1

Socket A Contactor control, 24 volts dc

Socket B Contact closure to A, completes 24 volts dc contactorcontrol circuit and enables output

Socket G Chassis ground

Socket I Normally open valid arc relay

Socket J Circuit common for valid arc relay

To use the Remote Process Select function for a given program, select the TIG process on the front panel while the desired programis selected.

OM-358 Page 19

3-9. Gas Connections

ST-801 866

1 Gas FittingFittings have 5/8-18 right-handthreads.2 Cylinder ValveOpen valve slightly so gas flowblows dirt from valve. Close valve.3 Regulator/Flowmeter4 Flow AdjustTypical flow rate is 15 cfh (cubic feetper hour).Connect customer supplied gashose between regulator/flowmeterand gas fitting on rear of unit.

Tools Needed:

3 24

1

5/8, 1-1/8 in

3-10. Electrical Service GuideA. For Multivoltage Units

Actual input voltage cannot exceed 10% of indicated required input voltage. Ifactual input voltage is outside of this range, no output is available.

NOTE

Three-Phase Single-PhaseInput Voltage 230 460 230 460

Input Amperes At Rated OutputAC 26.5 17.9 62.6 32.2

Input Amperes At Rated OutputDC 20.5 13.4 44 25.8

Max Recommended Standard Fuse Or Circuit BreakerRating In Amperes 50 25 100 50

Min Input Conductor Size In AWG/Kcmil 10 14 8 10

Max Recommended Input Conductor Length In Feet (Meters) 104 (32) 165 (50) 90 (27) 241 (74)

Min Grounding Conductor Size In AWG/Kcmil 10 14 8 10

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

B. For Single Voltage Units

Input Voltage 400

Input Amperes At Rated Output 20.2

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 30

Min Input Conductor Size In AWG/Kcmil 14

Max Recommended Input Conductor Length In Feet (Meters) 125 (38)Min Grounding Conductor Size In AWG/Kcmil 14

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

OM-358 Page 20

3-11. Connecting Input PowerCheck input voltage available atsite.1 Input And Grounding

Conductors2 Line Disconnect DeviceSee Section 3-10.For non-CE three-phaseoperation: Always connect green wire

to supply grounding termi-nal, never to a line terminal.

Connect black, white, and red wires(L1, L2, L3) to line terminals.For CE three-phaseoperation: Always connect green/yel-

low wire to supply ground-ing terminal, never to a lineterminal.

Connect black, brown, and bluewires (L1, L2, L3) to line terminals.For single-phase operation: Always connect green wire

to supply grounding termi-nal, never to a line terminal.

3 Black And White InputConductor

4 Red Input Conductor5 Insulation Sleeving6 Electrical TapeInsulate and isolate red conductoras shown.

L1

22

1

1

1

3

1

65

4

L2L3

L1L2

Always connect groundingconductor first.

13

= GND/PE

Green OrGreen/Yellow

Green

Green

input_2 3/96 - ST-802 136-A

OM-358 Page 21

SECTION 4 OPERATION4-1. Controls

A. For 230/460 Volts And Non CE Units (Use With Section 4-2)

Ref. ST-188 477-A

30

Rear Panel

1

3

4

8

9

10

11

12

16 17 18 19 13

2

5

2021

22

6

7

27

29

14 15

28

26

23

24

25

TIG Function Keys Stick Function KeysMemoryFunction

Keys

OM-358 Page 22

B. For CE Units (Use With Section 4-2)

ST-186 714-A / Ref. ST-801 866

1

3

4

6

78

9

1011

12

27

29

16 17 18 19 13 14 15TIG Function Keys Stick Function Keys

2

28

26

5

23

30

Rear Panel

MemoryFunction

Keys

24

2021

22

25

OM-358 Page 23

4-2. Description Of Controls (Use With Sections A And B) For all front panel switch pad controls:

press switch pad to turn on light and enablefunction.

1 Remote Trigger (Normal) ModeSee Section 4-3.2 Remote Trigger (2T) Hold ModeSee Section 4-4.3 4T Mode (Specific Trigger Method)See Section 4-5.To reconfigure 4T control for use as Spot, Con-tactor On Lift-Arc , and Mini Logic control, seeSection 4-6.4 Lift-Arc Start ModeSee Section 4-10.5 HF Start ModeSee Section 4-10.6 Encoder ControlUse Encoder Control in conjunction with appli-cable front panel function switch pads tochange values for that function.7 AmmeterDisplays amperage and preset parameters forpulse frequency, % of background amperage,% of dig, and % of peak time.8 VoltmeterDisplays arc voltage and the following presettimes (preflow, initial slope, final slope, andpostflow) in seconds, for applicable functioncontrols.9 Preflow Time ControlPress switch pad and turn Encoder Control toset time, 015 seconds, gas flows before weld-ing electrode is energized. Preflow control isdisabled if Lift-Arc Start mode is selected.Application:Preflow is used to purge the immediate weldarea of atmosphere. Preflow also aids in con-sistent arc starting.10 Initial Amperage ControlPress switch pad and turn Encoder Control toselect a starting amperage, 5300 amps, thatis different from the weld amperage.Application:Start current can be used while GTAW weldingto assist in preheating a cold material prior todepositing filler material.11 Initial Slope Time ControlPress switch pad and turn Encoder Control toselect length of time, 025 seconds, that ittakes to slope the amperage up/down fromstart amperage to weld amperage.12 TIG Weld Amps And Peak Amps When

Pulse Is SelectedPress switch pad and turn Encoder Control toselect 5300 amps for TIG welding or peakamps while pulsing.13 Final Slope Time ControlPress switch pad and turn Encoder Control toselect length of time, 025 seconds, that it ta-kes to slope the amperage up/down from weldamperage to final amperage.

Application:Final Slope Time should be used while GTAWwelding materials that are crack sensitive, and/or the operator wants to eliminate the crater atthe end of the weld.Note: This applies if the operator is using anon/off only type control to start and stop thewelding process.14 Final Amperage ControlPress switch pad and turn Encoder Control toselect 5300 amps of final amperage. Finalamperage is the amperage to which the weldamperage has sloped up/down to.15 Postflow Time ControlPress switch pad and turn Encoder Control toset time, 050 seconds, gas flows after weldingstops.Application:Postflow is required to cool tungsten and weld,and to prevent contamination of tungsten andweld. Increase postflow time if tungsten orwelds are dark in appearance.16 Pulser On/Off ControlPress switch pad to turn on light and enablepulser function.Application:Pulsing refers to the alternating raising andlowering of the weld output at a specific rate.The raised portions of the weld output are con-trolled in width, height, and frequency, formingpulses of weld output. These pulses and thelower amperage level between them (called thebackground amperage) alternately heat andcool the molten weld puddle. The combined ef-fect gives the operator better control of pene-tration, bead width, crowning, undercutting,and heat input. Controls can be adjusted whilewelding.Pulsing can also be used for filler material addi-tion technique training.17 Pulse Frequency ControlPress switch pad and turn Encoder Control toset pulse frequency, .1500 pps (pulses persecond).18 Pulse Width ControlPress switch pad and turn Encoder Control toset percentage of time, 595%, amperage is atpeak for each pulse.19 Background Amperage ControlPress switch pad and turn Encoder Control toset background amperage as a percentage,595%, of peak amperage.20 AC TIG Process Select ModePress switch pad to select AC TIG Process.21 AC Frequency ControlPress switch pad and turn Encoder Control toset AC frequency from 20250 Hz (cycles persecond). AC Frequency Control is enabledonly if AC TIG process is selected.Application:AC frequency controls bead width and direc-tional control. As AC frequency decreases,weld bead/puddle gets wider. As AC frequency

increases, weld bead/puddle becomes nar-rower and the arc becomes more focused.Travel speed can increase as AC frequency in-creases.

22 AC Balance ControlPress switch pad and turn Encoder Control toset percentage of time, 5090%, polarity iselectrode negative. AC Balance Control is en-abled only if AC TIG process is selected.Application:When welding on oxide forming materials suchas aluminum or magnesium, excess cleaningis not necessary. To produce a good weld, onlya minimal amount, approximately a 0.10 in(2.5mm) of etched zone along the weld toes isrequired.Joint configuration, set-up, process variables,and oxide thickness may affect setting.Arc rectification can occur when welding above200 amps and/or while welding with heliumgas. If this condition occurs, increasing the Bal-ance control towards maximum penetration,may help to restabilize the arc.

23 DC TIG Process Select ModePress switch pad to select DCEN (direct cur-rent electrode negative) TIG process.24 14 Program StorageEach program switch pad, 14, is capable ofstoring four welding parameter programs. Fourfor AC TIG, four for DCEN TIG, four for ACSick, and four for DCEP (direct current elec-trode positive) Stick. Depending on which pro-cess is selected, a total of 16 welding parame-ter programs can be recalled. The welding pa-rameters are updated to the selected memoryposition any time a parameter is changed. Torecall a program, press the desired process se-lect switch pad, and program pad 14.25 AC Stick Process Select ModePress switch pad to select AC Stick process.AC frequency is fixed at 60 Hz, and AC balanceis fixed at 50% EN (electrode negative). Whenthe AC Stick Process is select, the DIG func-tion is disabled.26 DC Stick Process Select ModePress switch pad to select DCEP Stick pro-cess.

27 Output Contactor Control (Stick)Press switch pad to enable/disable output.28 Stick Amperage ControlPress switch pad and turn Encoder Control toselect 5300 amps for Stick welding.29 DIG ControlPress switch pad and adjust Encoder Controlto set DIG (0100%).When set lower, short-circuit amperage at lowarc voltage is the same as normal welding am-perage.When set higher, short-circuit amperage is in-creased at low arc voltage to help with arc start-ing and making overhead or vertical welds, aswell as to reduce sticking while welding.30 Power On/Off SwitchSwitch located on rear panel.

OM-358 Page 24

4-3. Remote Trigger (Normal) Mode1 Remote Switch PadPress switch pad to activate func-tion.Torch trigger operation is as shown.NOTE: When a foot or finger remotecontrol is connected to the weldingpower source, initial amps, initialslope, final slope, and final amps arenot functional.NOTE: Initial weld amperage and fi-nal amperage is controlled by the re-mote device, not by the weldingpower source.NOTE: If On/Off only type trigger isused, it must be a maintained switch.All functions become active.Application: Use Remote Triggerwhen the operator desires to use afoot pedal or finger amperage con-trol.

Current (A)

Preflow

Initial Amps

Initial Slope Final Slope

Postflow

Weld Amps

Final Amps

1

Push & HoldFoot Or FingerRemote Control

Release ForMaintained Switch

Torch Trigger Operation

Release Foot Or Fin-ger Remote Control

OM-358 Page 25

4-4. Remote Trigger (2T) Hold Mode1 Remote Trigger Hold Switch

PadPress switch pad to activate func-tion.Torch trigger operation is as shown.NOTE: When a foot or finger remotecontrol is connected to the weldingpower source, only trigger input isfunctional.NOTE: Amperage is controlled bythe welding power source.Application: Use Remote TriggerHold (2T) when long extended weldsare made. Remote Trigger Hold (2T)can help to reduce operator fatigue.

Current (A)

Preflow

Initial Amps

Initial Slope Final Slope

Postflow

Push & Release TriggerIn Less Than 3/4 Sec.

Weld Amps

Final Amps

1

NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Normal) mode (see Section 4-3). Ifarc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-3).

Torch Trigger Operation

Push & Release TriggerIn Less Than 3/4 Sec.

OM-358 Page 26

4-5. 4T (Specific Trigger Method)1 4T Switch PadPress switch pad to activate func-tion.Torch trigger operation is as shown.While in 4T mode, there is a featureavailable during the main weld se-quence that allows the operator totoggle between weld current andfinal current without breaking thearc.

NOTE: When a remote switch isconnected to the welding powersource, only trigger input is function-al. Amperage is controlled by thewelding power source.Application:Use 4T trigger method when thefunctions of a remote current controlare desired, but only a remote on/offcontrol is available.

Current (A)

Preflow

Initial Amps

Initial Slope Final Slope

Postflow

Push & HoldTrigger

ReleaseTrigger

Push & HoldTrigger

ReleaseTrigger

Push & ReleaseTrigger In LessThan 3/4 Sec.

Weld Amps

Final Amps

1

Torch Trigger Operation

Push & ReleaseTrigger In LessThan 3/4 Sec.

OM-358 Page 27

4-6. Reconfiguring 4T For Mini Logic Control, Spot, Or Contactor On Lift-Arc1 4T Switch Pad2 Power SwitchTo reconfigure 4T, push and hold 4Tswitch pad and turn On powerswitch. Hold switch pad for approxi-mately 7 seconds (or until softwareversion number _ _ _ _ _ _-_clears,and meters display [-] [H4]).3 Encoder ControlUse Encoder to change functions.Active function will be displayed onamperage (right) meter.4 Meter DisplaysMeter displays for the different func-tions will be as shown.Press torch trigger or turn power Offto save setting. Lift-Arc requires apower down.Proceed to Section 4-7 for Mini Logicoperation.Proceed to Section 4-8 for Spot Con-trol Operation.Proceed to Section 4-9 for ContactorOn Lift-Arc Operation.

1

Rear Panel

2

3

H4

H4L

SPO

O1

=

=

=

=

4T (See Section 4-5)

Mini Logic (See Section 4-7)

Spot (See Section 4-8)

Lift-Arc (See Section 4-9)

4

H4

OM-358 Page 28

4-7. Mini Logic Operation1 Mini Logic Meter DisplaySelect Mini Logic according to Sec-tion 4-6.Torch trigger operation is as shown.During Mini Logic welding opera-tion, the weld current can be manu-ally changed from the initial ampslevel to the main weld amps level bypressing and releasing the torchtrigger in less than 3/4 seconds.Application: This ability to changecurrent levels without either initialslope or final slope, gives the oper-ator the opportunity to adjust fillermetal without breaking the arc.NOTE: When a remote switch isconnected to the welding powersource, only trigger input is func-tional. Amperage is controlled bythe welding power source.

Current (A)

Preflow

Start Amps

Initial Slope Final Slope

Postflow

Weld Amps

Push & HoldTrigger For MoreThan 3/4 Sec.

H4L= Mini Logic

1

Torch Trigger Operation

Push & HoldTrigger

Release Trigger

Final SlopeRate

Push & ReleaseTrigger In LessThan 3/4 Sec.

Final SlopeRate

Initial Amps

Push & ReleaseTrigger In LessThan 3/4 Sec.

Push & HoldTrigger For MoreThan 3/4 Sec.

Push & ReleaseTrigger In LessThan 3/4 Sec.

Push & ReleaseTrigger In LessThan 3/4 Sec.

Push & HoldTrigger For MoreThan 3/4 Sec.

OM-358 Page 29

4-8. Spot Control Operation1 Spot Function Meter DisplaySelect Spot function according toSection 4-6.2 TIG Weld Amps And Peak

Amps While Pulsing SwitchPad

3 Encoder ControlSet spot parameters as follows:Press switch pad once (amps LEDlights) and turn Encoder to set spotamperage. Press switch pad again(seconds LED lights) and turn En-coder to set spot time (.125 sec-onds).Torch trigger operation is as shown.NOTE: When a remote switch isconnected to the welding powersource, only trigger input is func-tional. Amperage is controlled bythe welding power source.Application: To provide a timedweld. Used for tacking, and thinsheet joining.

Current (A)

Preflow Postflow

Timed Spot Weld Amps

Push & HoldTrigger

ReleaseTrigger

SPO = Spot

13

2

Torch Trigger Operation

NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will bedisplayed (see Section 5-3).

OM-358 Page 30

4-9. Contactor On Lift-Arc Operation1 Contactor On Lift-Arc Meter

DisplaySelect Contactor On Lift-Arc func-tion according to Section 4-6.Proceed to Section 4-10 Lift-Arcstart procedures.Application: Lift-Arc is used for theDCEN GTAW process when the HFstart method is not permitted, or toreplace the scratch start method.Also, allows for the use of Lift-Arcwithout a remote on/off switch.

O1= Lift-Arc

1

NOTE: Preflow is a manual function and begins when the tungsten contacts the weldment. The length of time is determined by theoperator. Postflow is a timed function, and begins when the arc is manually broken.

4-10. Lift-Arc And HF TIG Start ProceduresLift-Arc StartWhen Lift-Arc button light is On,start arc as follows:1 TIG Electrode2 WorkpieceTouch tungsten electrode to work-piece at weld start point, enable out-put with torch trigger, foot control, orhand control. Hold electrode toworkpiece for 1-2 seconds, andslowly lift electrode. An arc will formwhen electrode is lifted.Normal open-circuit voltage is notpresent before tungsten electrodetouches workpiece; only a lowsensing voltage is present betweenelectrode and workpiece. Thesolid-state output contactor doesnot energize until after electrode istouching workpiece. This allowselectrode to touch workpiece with-out overheating, sticking, or gettingcontaminated.Application:Lift-Arc is used for the DCENGTAW process when HF Startmethod is not permitted, or to re-place the scratch method.HF StartWhen HF Start button light is On,start arc as follows:High frequency turns on to helpstart arc when output is enabled.High frequency turns off when arc isstarted, and turns on whenever arcis broken to help restart arc.

1

1 2SecondsTouch

Do NOT Strike Like A Match!

2

Ref. ST-156 279

OM-358 Page 31

4-11. Programmable HF Start Amperage And Time Modes

A. Accessing Programmable HF Start Amperage And Time ModesNOTE: Before accessing program-mable HF start amperage and timemodes, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile programmable HF start andtime modes are active.1 Lift-Arc And HF Start Mode

Key Pads2 Power SwitchTo display the programmable HFstart amperage and time screens,push and hold Lift-Arc and HF Startswitch pads and turn On powerswitch. Hold switch pads forapproximately 7 seconds (or untilsoftware version number _ _ _ _ __-_clears meters).Proceed to Section B and/or C.

1

Rear Panel

2

B. Setting Programmable HF Start Amperage

NOTE: Before accessing programmableHF start amperage mode, be sure that allprocedures and parameters are estab-lished. Parameter adjustment is limitedwhile programmable HF start amperagemode is active.

Welding cycle can be executed while inprogrammable start mode, but program pa-rameters cannot be adjusted while in thismode.

1 Initial Amps Switch Pad

2 Memory Program Switch Pads (14)3 Encoder ControlTo adjust DCEN or AC HF start amperageproceed as follows:Press desired TIG process switch pad (ACTIG or DC TIG) to activate desired processand turn On LED.Press desired memory switch pad (14) toactivate desired memory program and turnon LED.Press Initial Amps switch pad. Switch padLED turns on, meter A LED turns on, and[5 ] [30 ] is displayed on meters.

The 30 displayed on the amps meter isAC start amps and 20 is DC start amps(these are factory default settings), and canbe adjusted from 1 to 200 amps by turningthe Encoder control.To change start time, proceed to Section C.To save changes to HF start amperagewithout changing start time, select a differ-ent memory program number, or turn pow-er Off.

2

1

3

5 30

Or

OM-358 Page 32

C. Setting Programmable Start Time

2

1

NOTE: Before accessing programmablestart time mode, be sure that all proceduresand parameters are established. Parame-ter adjustment is limited while program-mable start time mode is active.Welding cycle can be executed while inprogrammable start mode, but program pa-rameters cannot be adjusted while in thismode.1 Initial Slope Switch Pad2 Memory Program Switch Pads (14)

3 Encoder ControlTo adjust start time proceed as follows:Press desired TIG process switch pad (ACTIG or DC TIG) to activate desired processand turn On LED.

If you are adjusting start time without hav-ing adjusted start amperage in Section B,press desired memory switch pads (14) toactivate desired memory program and turnon LED.

Press Initial Slope switch pad. Switch padLED turns on, meter S LED turns on, and[5 ] [20] is displayed on meters.The [20 ] displayed on the amps meter is ACstart time, and [3 ] is DC start time (theseare factory default settings), and can be ad-justed from 1 to 200 milliseconds by turningthe Encoder control.To save changes, select a differentmemory program number, or turn powerOff.

3

5 20

Or

OM-358 Page 33

4-12. Arc Timer/Counter Display1 Initial And Final Slope Control

Switch Pads2 Power SwitchTo display the arc timer/counter,push and hold Initial and Final Slopecontrol switch pads, and turn OnPower switch. Hold switch pads forapproximately 7 seconds (or untilsoftware version number _ _ _ _ _ _-_clears meters).3 Arc Timer DisplayUpon power up as describedabove, the meter S and Memory 1LEDs will turn on, and arc time willbe displayed for 5 seconds as [000000 ] to [999 999 ]. The first four num-bers indicate hours, and the last twonumbers indicate minutes. Arc timeshown in example is read as 1,234hours and 56 minutes. Maximumarc time is 9,999 hours and 59 min-utes.4 Arc CounterAfter 5 seconds, the meter A andMemory 2 LEDs turn on, and the arccounter will be displayed for thenext 5 seconds as [000 000 ] to [999999]. The maximum arc cycle countis 999 999.

1 1

Arc Timer 3

Arc Counter

1 2 3 4 5 6

49 9 9

Rear Panel

2

9 9 9

And

OM-358 Page 34

4-13. Lock Out Functions

A. Accessing Lock Out Capability

See Section 4-1 for explanation of controls referred to in all ofSection 4-13.There are four (14) different lock out levels. Each successive levelallows the operator more flexibility.NOTE: Before activating lock out levels, be sure that all proceduresand parameters are established. Parameter adjustment is limitedwhile lock out levels are active.1 Memory Program Buttons 3 And 42 Power SwitchTo access lock-out screens, press and hold memory program switchpads 3 and 4, and turn On power switch. Hold switch pads forapproximately 7 seconds (or until software version number _ _ _ __ _-_clears meters).3 Lock Out OffIf meter display is as shown, lockout feature is off.4 Lock-Out OnIf meter display is as shown, lockout feature is on.To turn On the lock out feature, proceed as follows:Enter a three digit code using the four Memory Program switch pads.NOTE: If any switch pad other than a numbered Memory Program

switch pad is used, the lock out code is cancelled, and the lock outcondition will remain inactive.Once three digits have been entered, the amperage screen displaywill change from [L0 ] to [L ].There are four lock out levels available. Enter any single digit (14),using the Memory Program switch pads, to access a lock out level(see Sections B and/or A).Press torch trigger or turn Off power to complete lock out Onsequence.To turn Off the lock out feature, proceed as follows:To access lock-out screens, press and hold memory program switchpads 3 and 4, and turn On power switch. Hold switch pads forapproximately 7 seconds (or until software version number _ _ _ _ _ _-_clears meters).Enter the same three digits that were used to turn on the lock out fea-ture. NOTE: If any switch pad other than a numbered Memory Pro-gram key pad is used, the code is cancelled, and the lock out condi-tion will remain On.Once the correct three digits have been entered, the amperagescreen display will change from [L1 ] or 2,3,4 to [L0 ].Press torch trigger or turn Off power to complete lock out Offsequence.

Rear Panel

2

1

3

4

or 2,3,4 L1

L 0

OM-358 Page 35

B. Lock Out Levels

Level 1NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile lock out levels are active.NOTE: Remote amperage controlis not available in level 1.Trigger SelectionAllows for normal, 2T, or 4T triggermode to be selected if the TIG pro-cess was selected when lock outfeature was activated.Stick Contactor ControlAllows for contactor control if theStick process was selected whenlock out feature was activated.Level 2NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile lock out levels are active.NOTE: Remote amperage controlis not available in level 2.Includes all the functions of level 1plus the following:Program Selection 14Gives operator the ability to selectdesired program.Process Selection TIG or StickGives operator the ability to selectthe TIG or Stick process.Lift-Arc Or HF Start ModeGives operator the ability to selectLift-Arc or HF Start mode.

Select TIG

Contactor Control (Stick)

Process Selection

Program Selection

Lift-Arc Or HF Start Mode Selection

Level 1

Level 2

Or

or Stick

Select desired program

Select Lift-Arc OrHF Start mode

Trigger Selection (TIG)

Or

Or

Or

OM-358 Page 36

C. Lock Out Levels (Continued)

Level 3

+/ 10 % Amperage Adjust Control

Select TIG or StickAmperage control,and use Encoder toadjust amperage.

Level 4

Remote Amperage Control

Level 3NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established. Pa-rameter adjustment is limited whilelock out levels are active.Note: Remote amperage control isnot available in level 3.Includes all the functions of levels 1and 2 plus the following:+/ 10% adjustment of preset TIGWeld Amps or Peak Amps WhilePulsing or Stick Weld AmpsSelect desired amperage control(TIG or Stick, and use Encoder con-trol to adjust amperage +/ 10% ofpreset amperage value, up to thelimits of the machine.Pulser ON/Off ControlGives operator the ability to turn on/off the Pulser control.Level 4NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established. Pa-rameter adjustment is limited whilelock out levels are active.Includes all the functions of levels 1,2, and 3 plus the following:Remote Amperage ControlAllows operator to use remote am-perage control if desired. Remotecontrol operates from minimum tomaximum of preset amperage val-ue. Connect remote control deviceaccording to Section 3-7.

A JB K I

C L N HD M G

E F

Pulser On/Off ControlTurn Pulser control on/off

OM-358 Page 37

SECTION 5 MAINTENANCE AND TROUBLESHOOTING

5-1. Routine Maintenance

Disconnect power before maintaining.

3 Months

Replaceunreadablelabels.

Clean andtighten weldterminals.

Replace damagedgas hose.

Repair or replace crackedcables and cords.

6 Months

Blow out inside. During heavyservice, clean monthly.

5-2. Blowing Out Inside of Unit

ST-802 135-A

Do not remove case whenblowing out inside of unit.

To blow out unit, direct airflowthrough front and back louvers asshown.

OM-358 Page 38

5-3. Voltmeter/Ammeter Help Displays

All directions are in reference to thefront of the unit. All circuitry referred tois located inside the unit.

0 Help 0 DisplayIndicates a short in the thermal protectioncircuitry located on the left side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.1 Help 1 DisplayIndicates a malfunction in the primary pow-er circuit. Contact a Factory AuthorizedService Agent if this display is shown.2 Help 2 DisplayIndicates an open in the thermal protectioncircuitry located on the left side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.3 Help 3 DisplayIndicates the left side of the unit has over-heated. The unit has shut down to allow the

fan to cool it (see Section 3-3). Operationwill continue when the unit has cooled.4 Help 4 DisplayIndicates an open in the thermal protectioncircuitry located on the right side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.5 Help 5 DisplayIndicates the right side of the unit has over-heated. The unit has shut down to allow thefan to cool it (see Section 3-3). Operationwill continue when the unit has cooled.6 Help 6 DisplayIndicates that the input voltage is too lowand the unit has automatically shut down.Operation will continue when the voltage iswithin the operating range (10%). Have anelectrician check the input voltage if this dis-play is shown.7 Help 7 Display

Indicates that the input voltage is too highand the unit has automatically shut down.Operation will continue when the voltage iswithin the operating range (10%). Have anelectrician check the input voltage if this dis-play is shown.8 Help 8 DisplayIndicates a malfunction in the secondarypower circuit of the unit. Contact a FactoryAuthorized Service Agent if this display isshown.

9 Help 9 DisplayIndicates a short in the thermal protectioncircuitry located on the right side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.

10 Help 10 Display

Indicates torch trigger is depressed. Re-lease trigger to continue.

1AV

2AV

3AV

HE.L P1

HE.L P2

HE.L P3

4AV

HE.L P4

5AV

HE.L P5

6AV

HE.L P6

7AV

HE.L P7

8AV

HE.L P8

0V

HE.L P0

9AV

HE.L P9

10AV

HE.L P10

A

OM-358 Page 39

5-4. Troubleshooting

Trouble Remedy

No weld output; unit completelyinoperative.

Place line disconnect switch in On position (see Section 3-11).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-11).Check for proper input power connections (see Section 3-11).

No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14receptacle (see Sections 4-1 and 3-7).Input voltage outside acceptable range of variation (see Section 3-10).Check, repair, or replace remote control.

Unit overheated. Allow unit to cool with fan On (see Section 3-3).Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-6).

Clean and tighten all weld connections.

No 115 volts ac output at duplex recep-tacle.

Reset circuit breaker CB1 (see Section 3-5).

Fan not operating. Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

Wandering arc Use proper size tungsten.

Use properly prepared tungsten.

Reduce gas flow rate.

Tungsten electrode oxidizing and not re-maining bright after conclusion of weld.

Shield weld zone from drafts.maining bright after conclusion of weld.

Increase postflow time.

Check and tighten all gas fittings.

Water in torch. Refer to t