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DM172 200 May 1996 Elf. wlSerial Number KG117815 Miller. Processes TIG The Power ofBlue. (GTAW) Welding Stick With (SMAW) Welding Optional Equipment: Pulsed TIG (GTAW-P) Welding Description Arc Welding Power Source Maxstarfi 152 0 1911 Visit our website at wwwMIIlerWelds~com OWNERS MANUAL From Miller to You Thank you and you can congratulations on choosing Miller. Now get the job done and get it done right. We know you dont Thats have time to do it any other way. 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. 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. Today, the This Owners Miller help Manual is products. you protect designed to help you get the most out of your Please take time to read the yourself against potential Safety precautions. They hazards made installation and on will the worksite. Weve operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for jMIIllhIIIPr REGISTERED QUALITY SYSTEM some reason the unit needs ______________ repair, theres a section that will Troubleshooting help you what the is. The out figure problem parts list will then help you to decide which 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 in the U.S.A. to be registered to the iSO 9001 Quality System Standard. ~1~flft~3ft1ll1~! L~W Working as hard as you do every power source from Miller is backed by the most hassle-tree warranty in the business. Miller Electric manufactures of welders and welding For information products, to on a full line related other equipment. quality Miller contact your local Miller receive the latest full line individual catalog distributor catalog or sheets. To locate your nearest distributor call 1-800-4-A-Miller. ~I7A Miller w The Thwer ofBlue. Call 1 -800-4-A-MILLER for your local Miller distributor. TABLE OF CONTENTS SECTION 1 gives READ BEFORE USING 1-5. EMF Information 1-3. Your distributor - 1-4. 1-2. you SAFETY PRECAUTIONS Symbol Usage Arc Welding Hazards Additional Symbols For Installation, Operation, And Maintenance Principal Safety Standards 1-1. 1 1 1 3 3 4 Service You SECTION 1 always get the fast, 1-1. reliable response you need. Most replacement 1-2. CONSIGNES DE SECURITE Signification des symboles Dangers relatits au soudage a Iarc Dangers supplementaires en relation be in your hands in 24 hours. 1-3. Support 1-4. Principales normes 1-5. Information sur parts can Need fast answers to the Contact your distributor. The expertise of the distributor and Miller is SECTION 2 2-1. 2-2. help you, every the way. there to 2-3. les 5 avec Iinstallation, le fonctionnement 7 de sØcuritØ champs Ølectromagnetiques DEFINITIONS Manufacturers Warning Label Definitions For CE Products And Definitions SECTION 3INSTALLATION 3-1. And Overheating parts information for your 3-5. unit. To obtain Technical 3-6. contact your local 3-7. Electrical Service Guide Miller offers a Manual which more Technical 3-3. provides detailed seivice and Manual, a distributor. Your distributor can also supply you with Welding Process Manuals suchasSMAW, GTAW, GMAW, and GMAW-P. For practical information SECTION 4OPERATION 4-1. Front Panel Controls 4-2. Lift-Arc TIG Procedure SECTION 5 on welding, process applica tions, and Miller products, visit 3-4. following terms are interchangeably throughout this manual: used TIG GTAW Stick SMAW = = MAINTENANCE & TROUBLESHOOTING 12 13 14 15 15 15 16 16 17 17 Routine Maintenance 17 Replacing Power Cord In Non-CE Models Measuring Input Capacitor Voltage Troubleshooting 18 5-3. 18 19 SECTION 6 ELECTRICAL DIAGRAMS 20 SECTION 7 PARTS LIST 22 WARRANTY The 11 12 5-2. 5-4. www.MHlerWelds.com 9 11 5-1. website at our 8 12 Specifications Duty Cycle Volt-Ampere Curves Selecting A Location And Connecting Input Power Weld Output Receptacles And Selecting Cable Sizes Remote 14 Receptacle Information 3-2. 8 9 Label For CE Products Rating Symbols 5 5 et Ia maintenance tough welding questions? step of LIRE AVANT UTILISATION Declaration of Conformity For European Community (CE) Products Miller Electric Manufacturers Name: Manufacturers Address: Declares that the conforms to the Co. Spencer Street Appleton, WI 54914 USA 1635 W. IVlaxstarfi 1 52 product: following Mfg. Directives and Standards: Directives Electromagnetic compatibility Directives: 89/336/EEC, Low Voltage 92/31/EEC Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Electromagnetic compatibility (EMC) Product standard for EN50199: Safety Requirements Degrees for Arc of Protection August Welding Equipment part provided by Enclosures Insulation coordination for Part 1: European Contact: Mr. Luigi Vacchini, Managing Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy Fax: dec_conl 10/95 welding equipment: 1: EN 60974-1: 1989 (IP code): lEG 529:1989 equipment within low-voltage systems: Principles, requirements and tests: IEC 664-1: 1992 MILLER Telephone: arc 1995 39(02)98290-1 39(02)98281-552 Director SECTION 1 - SAFETY PRECAUTIONS READ BEFORE USING - som 1-1 Symbol Usage ~ Marks This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. special safety message. a ~ Means Note; not related. safety Arc Welding Hazards 1-2. A .:....:~.:.H: : Watch Out There are possible Means Warning hazards with this procedure! The possible hazards are shown in the adjoining symbols. AA A shown below symbols The to call attention to and are used throughout this manual Identify possible hazards. When you symbol, watch out, and follow the related instructions safety information given below is only a summary of the more complete safety Information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards. see the to avoid the hazard. The A Only qualified persons should install, operate, maintain, and repair this unit. A _nd_5/97 During operation, keep everybody, especially children, away. If earth with grounding Use only well-maintained Wear a Keep all Clamp harness if safety panels and Do not touch live electrical Wear worktable as near clamp single weld and Do not use AC output in damp areas, if movement is confined, there is a danger of falling. Use AC If AC or if output required, use remote output control if present on unit. Disconnect input power or stop engine before installing or equipment. Lockout/tagout input power according CFR 191 0.147 (see Safety Standards). this to OSHA 29 Properly install Owners ground and this equipment according to its Manual and national, state, and local codes. making input connections, conductor first attach proper grounding 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 Do not worn, damaged, undersized, Do not use drape cables when not in over as when not connected to workpiece to prevent object. than more workpiece practical. one electrode or work cable to any FUMESANDGASEScanbehazardous 1~ =~-H If inside, use. your body. or Welding produces fumes these fumes and gases health. head out of the fumes. Do not breathe the fumes. ventilate the welding fumes If ventilation is poor, Read the and gases. Breathing be hazardous to your can Material manufacturers and/or area use exhaust at the arc to and gases. use an approved air-supplied respirator. Safety Data Sheets (MSDSs) instructions for metals, consumables, and the coatings, cleaners, and degreasers. Work in Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When good the weld Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. remove servicing place. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Keep your output ONLY if required for the welding process. is in metal-to-metal contact to output terminal. ~ ground using dry insulating mats prevent any physical contact with the to above floor level. securely body protection. from work and yourself or covers big enough work or ground. working parts. dry, hole-free insulating gloves Insulate ground, equipment. Repair or replace damaged according to manual. covers work cable with Do not connect electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. required, ground it directly clamp or work cable. at once. Maintain unit parts contact with any metal live Touching is work use Do not touch electrode if you are in contact with the work, another electrode from a different machine. Insulate work ~ workpiece do not or or ELECTRIC SHOCKcan~kflL of the separate cable a poorly spliced cables. a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, operations. The heat and rays of the form highly toxic and Do not weld irritating arc can or spraying react with vapors to gases. coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while on wearing an air-supplied respirator. The coatings and any metals containing these elements can give oft toxic fumes if welded. OM-172 200 Page 1 ARC RAYS bum can ~POFGAScannIurŁorkiU. eyesandŁkIn~.... Shutoff shielding gas supply when not in Always ventilate confined spaces or approved air-supplied respirator. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. use. use Wear a welding helmet fitted with a propershade of filterto protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Wear Safety Standards). approved safety glasses bumL.~ HOT PARTSCaæ: causesivere I with side shields under your helmet. Do not touch hot Use Allow protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. parts bare handed. cooling period before working on gun or torch. Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection. WELDING can cause fire or explosion Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, I I MACLDScanaffectpacemakers~ I Pacemaker ~~ yourself and others from Do not weld where flying sparks flying sparks can NOISEcan Noise from strike flammable material. that aware can cause fire Do not weld on welding on a extinguisher nearby. ceiling, floor, bulkhead, closed containers such Connect work cable to the work unknown Do not prevent welding paths use some processes or equipment can Wear approved ear protection if noise level is high. CYLINDERS can explode if damaged~ partition or the hidden side. as tanks, drums, they are properly prepared according Safety Standards). to damage hearhig.~:. fire on a unless practical spot or damage hearing. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Be away. and hot metal. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Watch for fire, and keep keep going near arc welding, gouging, welding operations. ____________ hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect wearers Wearers should consult their doctor before and as welding area as traveling long, possibly electric shock and fire hazards. welder to thaw frozen Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. pipes, (see close to the current from causing or to AWS F4.1 pipes. Remove stick electrode from holder tip when not in use. or cut off welding wire at Protect compressed gas cylinders from excessive heat, shocks, slag, open flames, sparks, and arcs. mechanical Install cylinders in an upright position by securing to support or cylinder rack to prevent falling or tipping. a stationary contact Keep cylinders away from any welding or other electrical circuits. Wear oil-free Never protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane from your person before doing any welding. lighter or matches, drape Never allow Never weld a a welding welding on a torch over a gas cylinder. electrode to touch any pressurized cylinder cylinder. explosion will result. Use FLYING METAL can Injure eyes only correct shielding gas cylinders, regulators, hoses, fittings designed for the specific application; maintain them associated parts in good condition. Turn face away from valve outlet when Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear shields OM-172 200 Page 2 approved safety glasses with side even under your welding helmet. opening cylinder and and valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions associated Standards. equipment, compressed gas cylinders, publication P-i listed in Safety on and CGA 1-3 Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard Do not install place unit or MOVING PARTS near injury Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. on, over, or near combustible surfaces. Do not install unit can cause flammables. building wiring be sure power supply system is properly sized, rated, and protected to handle this unit. Do not overload :FAWNG UNIT ,an CaUSe.JnJUry. H F RADIATION can cause Interference lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipmentofadequatecapacitytoliftand Use support High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. unit. only qualified persons familiar with equipment perform this installation. Have using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of If electronic unit. The is user responsible for having a qualified electrician problem resulting from the correct any interference installation. promptly OVERUSE Allow can cause OVERHEATING cooling period; follow Reduce current starting to weld Do not block or reduce or rated duty cycle. duty cycle before the FCC about If notified by equipment at once. Have the installation interference, stop using the regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. again. filter airflow to unit. STATIC(ESD)candamagePc boards~ Put on handling grounded boards or wrist strap BEFORE parts. ARC WELDING Use proper static-proof bags and boxes store, move, or ship PC boards. can cause interference to Electromagnetic energy can interfere with electronic equipment such as computers and computer-driven equipment sensitive MOVING PARTS can cause such injury Keep away from moving parts. Keep away from pinch points such as as To reduce drive possible, rolls. sure WP04~..WiREC~fl caUSeinJury.~ Be until instructed to do is possible interference, keep weld cabtes as short as together, and down low, such as on the floor. welding operation equipment. sure according trigger area close Locate tronic Do not press gun robots. all equipment in the welding electromagnetically compatible. Be this welding 100 meters from any sensitive elec machine is installed and grounded to this manual. If interference still occurs, the user must take extra measures as moving the welding machine, using shielded cables, so. such point gun toward any part of the body, people, or any metal when threading welding wire. using Do not line filters, or shielding the work area. other 1-4 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49. 1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety 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 Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 Code, NFPA Standard 70, from National Fire Association, Batterymarch Park, Quincy, MA 02269. National Electrical Protection Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51 B, from National Batterymarch Park, Quincy, MA 02269. Fire Protection Association, OM-172 200 Page 3 EMF Information 1-5, Considerations About Welding And The Effects Of Low Electric And Magnetic Fields Frequency 1. Keep cables Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 2. Arrange 3. Do not coil years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding To or reduce cutting. magnetic Page 4 cables to or together by twisting one drape or taping side and away from the cables around your Keep welding power practical. source Connect work to and cables them. operator. body. as far away from opera- br as 5. clamp workpiece as close to the weld as possible. About Pacemakers: fields in the workplace, use the following Pacemakerwearersconsultyourdoctorfirst. If cleared byyourdoctor, following the above procedures is recommended. then procedures: OM-172 200 4. close SECTION 1 - CONSIGNES DE SECURITE UTI LISATION - LIRE AVANT som Signification 1-1 A identifie Signifie I -2 A symboles Signifie Mise en garde! Soyez vigilant! Cette procedure presente des risques de danger! Ceux-ci sont identities par des symboles adjacents aux directives. AA ~ des un message de sØcuritØ NOTA Co groupe do symboles signifie Mise en garde ! Soyez vigilant! II y a des risquos de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN MOUVEMENT0t aux PIECES CHAUDES. Reportez-vous aux symboles et aux directives ci-dossous atm de connaitre los mesures a prendre pour Øvitor tout danger. particulier. nest pas re/at!! a Ia sØcuritO. Dangers relatifs soudage au Ł Iarc Leo symboles prØsontØs ci-aprŁs sont utilisØs tout au long du present manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez leo directives mentionnØes af in dØviter tout danger. Les consignes de sØcuritØ prØsentees ci-aprŁs no font quo rØsumer lintormation contenue dane los normos do sØcuritØ ØnumØrØes A Ia section 1-4. Veuillez lire ot respecter toutos ces normes do sØcuritØ. A Linstallation, lutilisation, vent Atre contiØs A _nd_tre 5/97 quA lentretien reparations qualifiees. et lee dos personnes Au cours de lutilisation, tenirtouto personne A lØcart et ticuliŁrement los enfants. no doi plus par No pas toucher IØlectrode quand on est en contact avec Ia terre ou uno electrode provenant dune autre machine. piŁce, Ia Nutiliser quun materiel en bon Łtat. Reparer ou remplacer sur-le champ los piŁces endommagees. Entretenir lappareil conformŁment a ce manuel. Porter un hamais de sŁcuritØ Maintenir solidement en quand place on travaille en hauteur. tous les panneaux et capots. Fixer le cable de retourde tacon a obtenir un bon contact mØtal-mØtal avec Ia piŁce a souderou Ia table de travail, le plus prŁs possible do Ia soudure. Isoler Ia pince do masse quand pas mis a Ia piŁce pour Øviter le objet matallique. contact avoc tout UN CHOQ :LE~TRIQUE peut Un simple contact avec des pieces Olectriques peut provoquer une Olectrocution ou des b!essures graves. LØlectrode et le circuit do soudage sont sous tension des que lappareil est sur ON. Le circuit dentrØe et les circuits internes de lappareil sont ºgalement sous tension ace moment-l. En soudage semi-automatique ou automatique, le fil, le dŁvidoir, le logement des galets dentraThement et los piŁces mŁtalliques en contact avec le til de soudage sont sous tension. Des matØriels mal installØs ou ma! mis a Ia terre presentent un danger. Ne jamais toucher les ily a DU COURANT CONTINU IMPORTANT dans ies convertisseurs aprŁs Ia suppression de Ialimenta tion electrique. ArrOter los convertissours, dŁbrancher le courant electriquo, et dØ charger les condensateurs dalimentation selon los instructions indiquees dans Ia partie ontrotien avant do toucher les piŁces. piŁces electriques sous tension. protection secs ne comportant Porter des gants et des vØtements de pas de trous. ~LES FUMEES de Ia piŁce et de Ia terre au moyen do tapis ou dautres moyens isolants suftisamment grands pour empOcher le contact phy sique Øventuel avec Ia piŁce ou Ia terre. Sisoler Ne passe servir de source electrique courant electrique dans los humides, dans es endroits confines ou l o on risque do tomber. So servir dune source electrique courant de soudage to demande. zones electrique UNIQUEMENT silo =9 Le soudage genere des fumØes et dos gaz. Leur inhalation pout Otre dangereux pour votro sante. w Eloigner _____________ es procØde Si lutilisation dune source electrique courant electrique savŁre nØces saire, se servir de Ia fonction de tŁlŁcommande Si lappareil en est equipe. Couper lalimentation ou arrOter le moteur avant de procŁder a linstal lation, a Ia reparation ou a lentretien de lappareil. DØvorrouil!er lalimentation solon Ia nornie OSHA 29 CFR 1910.147 (voir normes de sØcu rite). Installeret mettre ala terre correctement cet appareil conformØment a et aux codes nationaux, provinciaux et son manuel dutilisation municipaux. Verifier et sassu Toujours verifier Ia terre du cordon dalimontation que le fil de terre du cordon dalimentation eSt bien raccordØ a Ia borne de terre du sectionneurou que Ia fiche du cordon est raccordŁe a une prise correctement mise a Ia terre. rer rospirer Lire les spØcif ications do sØcuntØ des matØnaux (MSDS5) et les ins tructions du fabricant concernant los mØtaux, les consommables, los revŒtements, los nettoyants et les degraisseurs. Travailler dans espace tone seulement siI est bien ventilØ ou alimentation dair. Demandertoujours a formØ do so tenir a proximitØ. Des fumŁes 01 un surveillant dment des gaz de soudage peuvent deplacer lair et abaissor 10 niveau doxygŁne provoquant des blessures ou des accidents mortols. Sassurer quo lair do respiration no presente aucun danger. en portant un un respirateura No pas souder dans dos endroits situØs a proximite dopŁrations do do nettoyage ou do pulvØrisation. La chaleur et los rayons do Iarc peuvent reagir en presence do vapours et former dos gaz hautement toxiques ot irritants. degraissage, frequemment le cordon dalimentation pour voir sil nest pas endommago ou dØnudØ remplacer le cordon immŁdiatemont sil ost endommage un cable denude pout provoquer une electrocution. Mettre lappareil hors tension quand on no lutilise pas. No pas utiliser des cables uses, endommages, do grosseur insuffi sante ou mal episses. galvanise, plaque Ne pas enrouler los cables autour du corps. Si Ia piŁce soudØe doit Œtre miso ala terre, le faire directoment avec un cable distinct no pas utiliser le connecteur do piŁce ou to cable do votre tŒte des fumØes. No pas fumØos. A IintØneur, ventiler Ia zone etlou utiliser un Øchappement au ni veau do larc pour IØvacuation des fumØes et des gaz do soudage. Si Ia ventilation est insuffisante, utiliser un respirateur a alimenta tion dair hornologue. En effectuant los raccordemonts dentrŁe fixer dabord le conducteur de mise a Ia terre appropnØ et contre-vØritier les connexions. Verifier ET LESGAZ peuvent Œtre dangereux No pas souder des mØtaux munis dun revOtement, tels quo Iacier en p10mb ou au cadmium a moms quo 10 revŒte mont nait Øte enlevØ dans Ia zone do soudure, quo Iendroit soit bien ventilØ, et si nØcessaire, en portant un rospirateur a alimenta lion dair. Los rovOtoments ot tous les mØtaux renfermant ces ele ments peuvent dŁgager dos fumØes toxiques en cas do soudage. retour. OM-172 200 Page 5 .GAZ rise :1-ES RAY0NSDEL~ARCpeuventpro~ voquer des briures dans leS yeux etr sur Is peau~ ....:..:.........:..:. Le rayonnement de larc du procØdØ do soudago genere des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brUlures dans los yeux et pendant le soudage. Ia peau. Des Øtincelles sont sur projetØes blessures ~cJ I Former lalimentation non rateur dadduction protections approuvØs feu Incendle peutprovoquer.un explosion ou une . Porteurs de stimulateurcardiaque, restoz distance. cardiaque doivent dabord consulter leurmØdecin avant de sapprocher des operations de soudage a larc, de gougeage ou do soudage par points. Les Le contact accidentel do lØlectrode avec des des Øtincellos, une explosion, un surchauffement ou un incendie. Avant do commoncer le soudage, verifier et sassurer quo londroit no prØsonto pas do danger. projection chaudes a mains parties LES CHAMPS M AGNETIQUES peUvŁiit: ~timulateurs car~j~que objets metalliques pout provoquor personnes do Ia respi PrØvoir une pØriode de refroidissemont avant dutiliser le pistolet ou Ia torche. soudago off ectuØ sur des conteneurs fermØs tels quo des reservoirs, tambours ou des conduites pout provoquerleureclatement. DesØtincelles pouventOtre projotØes do larc do souduro. La projection dØtincel los, des piŁces chaudes et des equipements chauds pout provoquer des Se proteger et dautres metal chaud. servirdun flues Le incendies et des brlures. ou se homologue. dair No pas toucher des protection constituØ dans une matiŁre dura (cuir ou lame) ot une protection des plods. LE SOUDAGE de .: Porter des vØtements do au en cas DES PIECES CHAUDES euvent pro voqerdesbru!u reS 9ra~es pour les oreilles Si le niveau sondre est trop ØlevØ. Utiliser des Øcrans ou des barriŁres pour proteger des tiers de lØclair et de leblouissement; demander aux autres personnes de no pas re garder larc. ble, resistant du gaz protecteur utilisation. Veillertoulours a bien aØrer los espaces confines Porter un casque de soudage muni dun Ocran de filtre appropriO pour protegervotre visage et vos yeux pendant 10 soudage ou pour regar der (voir ANSI Z49. 1 et Z87.1 ØnumØrØ dans los normos de sØcuritØ). Porter des ou i~mort~:: porteurs dun stimulateur dØtincelles et do RU1T peut affecter touie~ Ne pas souder dans un endroit l o sur des substances inflammables. des Øtincelles peuvent tombor Le bruit des processus et des louIe. DØplacertoutes les substances inflammables a une distance de 10,7 m de larc do soudage. En cas dimpossibilite los recouvrir soigneuse ment avec des protections homologues. Des tincelles et des matØriaux chauds du soudage peuvont facilemont passer dans dautres zones en traversant de petites fissures et Porter des equipements peut affecter protections approuvØs pour los oreilles Si le niveau sondre est trop ØlevØ. des ouvertures. SurveillertoutdOclenchementdincendieettenirun extincteur proxi SI des BOUTEILLES sont endofl qees~ elles pourront exploser mite. soudage effectuØ sur un plafond, plancher, paroi ou separation peut dØclencher un incendie do lautre ctŁ. Ne pas effectuer 10 soudage sur dos conteneurs fermØs tels quo des reservoirs, tambours, ou conduites, a moms quils naiont ete prepa rØs correctement conformØment a AWS F4.1 (voir los normes do sØcuritØ). Brancher 10 cable sur Ia piŁce le plus prŁs possible do Ia zone de sou dage pour Łviter le transport du courant sur une longue distance par dos chemins inconnus Øventuels on provoquant des risquos dØloc Le trocution et dincendie. No pas utiliser lees. posto do soudage pour dØgelor des conduites go 0 En cas do non utilisation, onlovor Ia baguette dŁlectrode Øtectrode ou couper Is hI a Ia pointe do contact. du porte Porter des vŒtements de protection dØpourvus dhuile tels que des gants en cuir, une chemise en matØriau lourd, des pantalons sans re vers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible do tellos quun allumeur au butane ou des allumettes. vos poches .. ~~:.DEs;pAR~cuLEsvoLANTEs peuvent blesse!lesyeux~.~. _____ soudage, lØcaillemont, tes. Pendant Ia do projeter du en fil de fer, et le laitier. Porter des lunettes de sØcuritØ OM-172 200 Is passage do Ia piŁce meulage generent des Łtincelles etdes particules mŁtalliquesvolan periode do ref roidissement des soudures, elles risquent Le Page 6 avec Øcrans lateraux ou un manipuler avec precaution. ProtØger les bouteilles de gaz comprime dune chaleur excessive, des chocs mecaniques, du laitier, des flammes ouvertes, des Øtin cellos et des arcs. Placer los bouteilles debout en los fixant dans un naire ou dans un de se renversor. Øcran facial. porte-bouteilles Ne jamais placer Une electrode do une bouteille. jamais souder pour les support station ompecher de eloignees des circuits de soudago ou Tenir los bouteillos cuits olectriques. Ne .. a Ia brosse Des bouteilles do gaz protecteur contiennent du gaz haute prossion. Si une bouteille est endomma gee, elle peut exploser. Du fait quo los bouteilles do gaz font normalement partie du procØdØ de soudage, los sous une torcho do soudago uno ne bouteille soudage sur une jamais entror doit pressurisØe tomber ou autres cir bouteille a gaz. en contact avoc risque dexplosion. Utiliser seulemont des bouteilles do gaz protecteur, regulatours, tuyaux et raccords convenables pour cette application specifique; los maintenir ainsi quo los ØlØmonts associØs en bon Øtat. No pas tenir Ia tŒte bouteille. Mamntenir 10 dutilisation en face do Ia sortie on ouvrant Ia soupapo do Ia do protection sur Ia soupape, sauf en cas de branchoment de Ia bouteille. chapeau ou Lire et suivre les instructions concemant los bouteilles do gaz corn les Øquipements associØs et les publications P-i CGA Ønu mØrØes dans los normes de sØcuritØ. prime, 1 -3~ Dangers supplØmentaires .:: etia maintenafl~e~~ en relation .;.~.., ....,. avec .: ... ou comme le panneaux, protection. FRE RAYON N EMENT;: HAUTE QUENCE :(H.F~:ri~ii de des Interferences. LA CHUTE DE:t?APPAREIL peU ..... i.... Maintenir fermŁs et fixement en place les portes, recouvrements et dispositifs de lappareil a proximitØ de produits inflammables Nepassurchargerlinstallationelectriquesassurerquelalimen tation est corroctement dimensionnØ et protØgØ avant do mettre lappareil en service. . MPBi~S::pe~vent: Rester a lØcart des organes mobiles ventilateur. a Ne pas installer biesser ::..~.:r:~:::.:~ :::... :Pr0v0~0r des .. Ne pas placer lappareil sur, au-dessus proximitØ de surfaces infllammables. i: ~ DES ORGANES Risque D~INCENDIE OU DEXPLOSION~ le fonctionnement tinstallation : .....:.. provoqUer . . Le engin dune capacitØ appropriØe pour lappareil. utilisant des fourches de levage pour dØplacer lunitØ, sassurer Utiliser un soulever En que los fourches sont suff isamment oppose de lappareil. IJEMPLOI longues pour dØpasser du ctO .:.: EXCESSIFpeut SuRcHAuFFERtEQVIPEMENT.:;~ une pØriodo do refroidissemont, respec cycle opØratoire nominal. RØduire 10 courant ou 10 cycle opØratoire avant do recommancer 10 soudago. PrØvoir rayonnement haute frequence peut provoquer des interferences avec les equipoments do ra dionavigation ot do communication, los services do sØcuritØ of los ordinateurs. Utilisorlanneaude levage uniquement pour sou lever lappareil, NON PAS les chariot, les bouteil los de gaz ou tout autre accessoire. Demander seulement a des personnes qualifiees familiarisØes des Øquipemonts electroniques de faire fonctionnor linstalla tion. avoc Lutilisateur ost tonu do faire qualifiØ corriger rapidemont par los interferences resultant do linstallation. Si le FCC roil. signale des interferences, Eftoctuer reguliŁrement lo contrle un Øloctricien arrOter immØdiatement et lentretien lappa do linstallation. Maintenir soigneusomont formØs los portes ot los pannoaux des sources do haute frequence, maintenir los Øclateurs a uno distance correcte ot utiliser uno terre et et un blindage pour rØduire los inter tØrencos Øventuelles. ter le No pas obstruer es A LARC ~~ovoquerdes Interfere LE SOUDAGE passages dair du poste. LES CHARGES ELECTROSTATiQUES. I peuvent endommager les. c ircults Im de risque LØnergie electromagnetiquo provoquor dos interferences pour lequipemont electronique sensible tel quo los ordinateurs ot lequipemont commandŁ par ordinateur tel quo los robots. . ~ prImes~ T. .: ::.:~ . Etablir Ia connexion avoc Ia barrette do terre manipuler des cartes ou des piŁces. avant do Utiliser des pochettes et des boites pour stocker, dØplacer ou circuits impnmes. O antistatiques expØdier des cartes do DES ORGANES MOBILES peuvent prOvoquer des blessure s. ~ :. .~ No pas sapprocher des organes mobiles. No pas sapprocher des points do coincement tels que des rouleaux do commando. FILSDESOUDAGE peuveætpro voquerdØsbies su !!L..... 1 LES . Veiller ace quo tout lequipement do Ia zone de soudage soil com patible eloctromagnØtiquement. Pour rØduire Ia possibilitØ dinterfØrence, maintonir los cables do soudage aussi courts quo possible, los groupor, ot los poser aussi bas quo possible (ox. par terre). Veiller a soudor a une distance do 100 metres do tout Øquipement eloctroniquo sensible. Veiller a ce quo co posto do soudago soit pose et mis a Ia terre conformØment a ce mode demploi. En cas dinterfØrences aprŁs avoir pris los mesures prØcØdentes, il incombe a lutilisateur do prondre dos mosuros supplØmontairos telles quo le dŁplacemont du poste, lutilisation do cables blindŁs, lutilisation do filtros do Iigne ou Ia pose do protecteurs dans Ia zone de travail. I MAGNETIQUES peuvent ~ LES CHAMPS affecter lee ... Porteurs do stimulateur No pas appuyor recu linstruction. No pas sonnes le til do sur gachotto avant don avoir pistolot vers soi, dautros per ou toute piŁce mØcanique en engageant soudago. dirigor 10 Ia risque de cardiaque, restez a dis tance. Los porteurs dun stimulateur cardiaquo doivent dabord consulter leur mØdecin avant do sappro cher des operations do soudago a larc, do gou geage ou do soudage par points. OM-172 200 Page 7 ii ~4~,.::i:PrinipÆ1es rl~orm es de SØcUritØ Safetyin Weldingand Cutting, norme ANSI Z49.1, de lAmerican ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 :: Wel Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of 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 AWS F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Mia mi FL 33126 National Electrical Code, tection Association, 1-5 NFPA Standard 70, de Ia National Fire Pro MA 02269. Batterymarch Park, Quincy, information sur les sur le soudage electrique ot sur los effets, pour lorganisme, champs magnOtiquos basse frOquence Safe :~ :::: Handling of Compressed Gases in Cylinders, CGA Pamphlet Regles de sØcuritØ en soudage, coupage etprocØdØs connexes, norCSA W11 7.2, de iAssociation canadienne do normalisation, vonto de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3. me 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 SiB, de Ia National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Atm do rØduire les champs electromagnetiques dana lenvironnement do travail, respecter los consignes suivantes 1 soudage, pendant son passage dans les cables de sou dage, causera des champs electromagnetiques. II y a eu et il y a encore un certain souci a propos de tels champs. Cependant, aprŁs avoir examine plus de 500 etudes qui ont ete faites pendant une p6node de recherche de 17 ans, un comitØ special ruban bleu du a ~ :: :~:::~:: P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. conclu: Laccumulation avec los torsadant en ou en les du ruban adhOsif. 2 Mettre tous los cables du ctØ 3 Ne pas courbor pas et no oppose do loperateur. pas entourer pas los cables autour do votre corps. 4 Garder le poste de do vous. 5 Relier Ia pince do soudure. do preuves, sui jugement du comitØ, na pas dØmontrØ quo lexposition aux champs magnetiques et champs electriques a haute frequence reprØ sente un risque a Ia sante humaine. Toutefois, des etudes sont Garder les cables ensembles attachant Le courant de National Research Council : : champs electromagnetiques DonnØes des ~ soudage et les cables le plus loin possible vant le en cours et los preuves continuent a Łtre examinØes. En at tendant quo los conclusions finales do Ia recherche soient Øtablies, il vous serait souhaitable de rØduire votre exposition aux champs Ølec toujours tromagnØtiques pendant OM-172 200 Page 8 le soudage ou 10 coupage. Consignes relatives masse aux le plus prbs possible stimulateurs de Ia zone de cardiaques Los personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous Otes dOclarO apte par votre docteur, ii est alors recommande do respecter los consignes cidessus. SECTION 2- DEFINITIONS 2-1. Manufacturers Warning Label Definitions For CE Products Warning! Watch Out! There possible hazards as shown by symbols. 1 Electric shock from electrode 1.1 Wear or wiring are the welding kill. can dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. yourself from electric shock by insulating yourself from work and ground. 1.2 Protect 1.3 Disconnect input plug power before working or on machine. fumes can be hazardous to your health. 2 Breathing welding 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation exhaust to remove or local the fumes. 2.3 Use ventilating fan to fumes. remove 3 Welding sparks can explosion or fire. 3.1 Keep flammables away from welding. Do not weld near cause flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. 3.3 Do not weld on drums closed containers. 4 or any Arc rays can burn eyes and injure skin. 4.1 Wear hat and Use shirt safety glasses. protection and button collar. Use welding ear helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on 6 the machine or Do not remove or (cover) the label. welding. paint over 1/96 OM-172 200 Page 9 1 2 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from kill. wiring can 3 Disconnect input plug working power before machine. 4 or on Hazardous on voltage remains input capacitors after power is turned off. Do not touch fully charged capacitors. wait 60 seconds after power is turned off before working on unit, OR 5 Always 6 Check input capacitor voltage, and be sure it is near 0 before touching any parts. 4/96 1 Warning! Watch Out! There possible hazards as shown by the symbols. are 2 When power is applied failed explode or cause other parts to explode. parts / / / / *1 I?~JH ?S~4~AI 3 can Flying pieces of parts can injury. Always wear a face shield when servicing cause unit. 4 Always 5 After wear long sleeves and button your collar when servicing unit. taking proper precautions as shown, connect power to unit. 4/96 OM-172 200 Page 10 2-2. Rating Label For CE Products ~IODI~i1-~ ICE 1EN60974-1 .-_ IN1OV i~r: Uo g Uo V 80 95 IJD~ / V ~ ~ ul I 150A/26V - X 12 U2 12 U2 60% 100% 120 25 120 15 150 26 150 16 V imax=32 ~o ieff=25 1P21 Ref. ST-179 381-A Symbols 2-3. I NOTE A And Definitions ~ Some symbols are found only CE products. on 5I~ Shielded Metal Arc Amperage Panel Output Lift-Arc Remote On Off High Temperature Negative Voltage Input Tungsten Arc Welding (GTAW) Protective Earth Direct Current Voltage Welding (SMAW) Gas Positive (DC) (Ground) Single-Phase Constant Current U0 I.~ 1~ Rated No Load Phase Conventional Load Primary Voltage Voltage (Average) PrimaryCurrent Single Static Frequency ConverterTransformer Rectifier 2 12 Rated Welding Current X Voltage Duty Cycle Line Connection P O~/o Degree Of Protection Percent OM-172 200 Page 11 SECTION 3- INSTALLATION N OTE 3-1. Unless otherwise noted, the CE model is shown ~ this manual. throughout Specifications Amperes Input at Rated Load Output, 50 Hz, Single-Phase Duty Cycle 100% . Rated Maximum Welding Output Open-Circuit Voltage DC Amperage Range IP 230 V Rating Overall KVA KW Weight Dimensions 150 A ' 26 Length: 16-1/2 (419 mm) Volts DC, 60% Duty 80 In SMAW 1150 120A@25 Volts 27.1 95 In GIAW DC, (0.5)* 21 6.2 (0.12) 3.7 Width: 9-1/2 in 31 lb (0.1)~ Mode95 100% Duty Cycle * While 3-2. in Height: 10 in (254 mm) idling Duty Cycle And Overheating rti ii: ~ Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. - 150 Gr~ lfunitoverheats,overtemperature light goes On and output stops. Let 8MIW fan run for fifteen minutes. Reduce or duty cycle before amperage 100 - - - - - - welding. A Exceeding duty cycle damage unit and void can war ranty. 50 -- 10 15 20 25 30 - 40 50 50703020100 X DUTY CYCLE 100% Duty Cycle Continuous 60% At 120 A Welding 6 Minutes Duty Cycle Welding At 150 A 4 Minutes Resting Overheating ~~ Minutes Reduce Duty Cycle dutyl OM-172 200 Page 12 4/95/ST-121 591-B 3-3. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage 100 and amperage output capabilities of the welding power source. Curves of other settings fall be 90 tween the curves shown. 80 70 ~60 -J 00 > ~40 30 20 10 0 0 50 100 150 DC AMPERES 200 250 ssbl.1 10/91 SB-151 604 OM-172 200 Page 13 3-4. Selecting A Location And Connecting Input Power r1~PH4~$ ~)lI~ G~ 1 Plate Label 2 Rating Label rating label to determine Use input power needs. 3 User-Supplied Plug 4 Receptacle (May Vary According To Location) Connect 5 plug to receptacle. Line Disconnect Device See Section 3-7. 5 A Special installation may be required where gasoline or volatile liquids are present NEC Article 511 Section 20. see or CEC Li 2 A Always connect grounding conductor first. = i,.ur GND/PE N~ eTocIcN~ ~U .-I~ HER1~ A Do not move or operate unit where it could tip. input_i 3/96 OM-172 200 Page 14 Ref. 5T-801 504 / Ref. 5T-801 603 3-5. Weld Output Receptacles ARC WELDING A ~ And can cause Selecting Electromagnetic Cable Sizes Interference. 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 To reduce installed and as moving grounded according to this manual. If interference still occurs, the user must take extra welding machine, using shielded cables, using line filters, or shielding the work area. Total Cable 100 ft (30 m) 1060% Welding Weld Output Terminals measures such the (Copper) Length 150ft Or Less In Weld Circuit Not 200ft (45 m) I I 250ft 300ft (70 m) (60 m) Exceeding (90 m) I I (105 m) 400ft (120 m) 60100% Amperes Duty Cycle 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 10 100% Duty Cycle + Output Receptacles Weld cable size 3-6. (AWG) is based Remote 14 on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-000l-D Receptacle Information Socket Information Socket* REMOTE 14 A G~WWUT (coNrPcroR) B +l5voltsdc. Contact closure to A completes +15 volts dc con tactor control circuit. C 0 to +10 volts dc pending REMOTE OUTPUT CONTROL on output setting of to remote control, de Amperage Adjustment control. E 0 to +10 volts dc mote control. D Remote control circuit K Chassis input command signal from re common. GND Ret. ST-801 603 The 3-7. remaining sockets are common. not used. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Reference: 1993 National Electrical Code Rating In Amperes (NEC). s-oos~j OM-1 72200 Page 15 SECTION 4- OPERATION 4-1. Front Panel Controls 1 2 3 8 4 5 6 7 Ref. ST-hg 381-A 1 2 Amperage Adjustment Control Amperage Control Switch For front panel control, place switch For weld in Panel position. For remote control, make connections to Remote 14 receptacle, and place switch in Remote 14 3 position. Output (Contactor) Switch OM-172 200 Page 16 output, place switch in On position. For remote control, make connections to Remote 14 receptacle, and place switch in Remote 14 position. 4 Lift-Arc Switch For Lift-Arc TIG place welding (see Section 4-2) position. Place switch in switch in On Off position for welding. other than 5 Power On/Off Switch 6 Pilot 7 Process Selector Switch 8 Over Lift-Arc TIG Light Only) Temperature Light (CE Models 4-2. Lift-Arc TIG Procedure With Lift-Arc Switch in the On ~1~ 2 posi start an arc as follows: tion, 1 TIG Electrode 2 Workpiece Touch tungsten piece at weld electrode to workstart point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted. 12 Seconds Touch Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present be tween electrode and workpiece. ! : The solid-state output contactor does not energize until after elec trode is touching workpiece. This allows electrode to touch workpiece without overheating, stick ing, or getting contaminated. Do NOT Strike Like A Match! Ret. S-156 279 SECTION 5- MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance OM-172 200 Page 17 5-2. Replacing Power Cord In Non-CE Models A Turn ~ ! Off welding power disconnect input source, power, and check voltage on ________________________________ input capacitor according to Section 5-3 before proceeding. Have only qualified procedure. persons carry out this Remove wrapper. 1 Input Terminal Block 2 Input Conductors 3 Grounding Conductor Disconnect input conductors and conductor from input terminal block. grounding 4 Strain Relief Connector Loosen strain relief connector and remove existing power cord. Be sure conductor rating of new cord complies with national, state, and local electrical codes. Strip 3/8 in (10 mm) insulation off all conductors. Insert conductors relief. through 5 Line Terminals 6 Ground Terminal strain Connect grounding conductor to ground terminal first. Connect input conductors to line terminals. Terminals are identified Li, L2, or L3 on terminal block. Reinstall wrapper. Ref. ST-801 603 / Ref. ST-801 300-A 5-3. Measuring Input Capacitor Voltage _________________________ A Significant DC voltage can remain on capacitor after unit is Off. Al ways check capacitor as shown to be sure it has discharged before working on unit. Turn Off welding power source and disconnect input power. Remove wrapper. 1 Input Capacitor Cl 2 Voltmeter Check input capacitor as shown. Measure dc voltage across posi (+) and negative () terminals until voltage drops to near 0 (zero) tive volts. Proceed with job inside unit. Reinstall wrapper when finished. Tools Needed: c::::::cJ=:==1J 5/16 in Ref. ST-801 603 OM-172 200 Page 18 Troubleshooting 5-4. ,u~d Remedy Trouble output; unit completely inoperative. No weld Place line disconnect switch in On Check and Check for proper No weld light output; on, fan Power switch pilot Check position fuse(s), line replace position (see Section 3-7). if necessary, connections input power Output (Contactor) of or switch. on. output with no control. output and low open-circuit position of Amperage Check Have Limited Factory Check Control switch Authorized Service Agent input power for correct voltage. (see Section 3-7). (see Section 3-2). (see Section 4-1). check control board PCi. Check and replace line fuse(s), if necessary, or reset circuit breaker voltage, Check for proper Erratic (see Section 3-7). (see Section 3-7). Unit overheated. Allow unit to cool with fan On Low weld reset circuit breaker or improper weld output. Clean and input Use proper size and Replace when Arc not forming Fan not operating. using Lift-Arc. Wandering arc; poor control of arc and (see Section 3-4). cable type of weld input output connections (see Sections 3-7 and 3-4). electrode. Check electrode and Check for and Have output connections (see Sections 3-7 and 3-4). all weld connections. tighten Check for proper and Factory workpiece, remove clean as anything blocking Authorized Service Agent needed to allow good fan movement; be contact. sure fan is secure on shaft. check fan motor. Reduce gas flow rate. direction. Select proper size tungsten. Properly prepare tungsten. Tungsten electrode oxidizing and not remaining bright after conclusion of Shield weld zone from drafts. weld. Increase posttlow time. Clean and tighten all gas fittings. Water in torch. Refer to torch Owners Manual for part(s) requiring replacement, and repair torch as necessary. OM-172 200 Page 19 Cl) m C) 0 z 0) m I m C) -I I D C) Cl) 0) 9 0) CO C -Il 0 1 N) 00 0) 0) N) 0 C -ICD P -I C) -I C) C 0) -I0) 3 -Il 0 -I z 0 C, m 0 0. CD 0) 0 L~ L1 a~f K C 0 IE 1~ I~1-~J ~15 ~1-2 ~-3 F~:1-~3 ~ I~9-4 I~9-1 ~a/~c8 ~3/~G3 ~Z4tG2 46 p~4~ Fc~-2 (I) o Co LA. a) I CD C) I C.) (5 I (5 E LA. 0 I () IL 0 (a, 0 F. c~J cj 0 0 a CO C) 0) cJ to 0 Co SECTION 7- PARTS LIST Hardware is common and not available unless listed. 3 4 6 7 24 25 Fig 15 26 46 ~ 27 43 28 40 37 ST-801 587 Figure OM-172 200 Page 22 7-1. Main Assembly (CE Model Illustrated) Item No. Dia. Part Na Mkgs. Description Figure 1 134 327 1 179 310 2 126 416 ... 3 126 415 ... 4 +163 781 5 PCi 5 PCi PLG1,2 ... PLG3 131 056 ... PLG5 ++130 203 ... .... Cl ii 12 13 Neg,Pos .... 15 16 TEl 19 19 CT1 21 22 23 24 24 25 26 Zi 27 HD1 PLG1O 1 1 CLAMP, saddle 1 WRAPPER 1 CONNECTOR & SOCKETS, CONNECTOR & SOCKETS CONNECTOR & SOCKETS 1 1 (international) 2 1 1 6 1 ... 1 ... 1 ... 2 1 1 1 ... 2 ... 2 .... 1 ... 1 1 1 156 149 . ...130 204 ...28 Ti 151585 29 R2 139203 30 Ri 136076 141422 Si 090328 PLG11 115094 RC11 115090 047 838 148297 030170 CR1 106462 ...36 010916 37 019663 ...38 181577 181578 FL1 ... 1 ... 1 ... 1 ... 1 1 1 ... 1 ... 1 ... 1 ... 1 ... 1 1 1 130 794... STABILIZER 114066 40 HANDLE ... 17 32 1 GROMMET, scr No. 8/10 panel hole .281 sq .197 high 140 627... INSULATION, PC card 151 280 BRACKET, mtg PC card 151 281 CAPACITOR, elctlt 1 600uf 400VDC 006 426... CLAMP, capacitor 2.000dia N UT, speed U type 10-32 136 190 133405... NUT, speed 10-24 flat type rectangular 130 215... PLATE, output rear panel 129 525 RECEPTACLE, twlk insul fern (Dinse type) 50/70 series 042 418 CONNECTOR KIT, Dinse male (consisting of) 134 746 WRENCH, hex 5mm short 169 777 CABLE, power 250V 6-50P 1 2ga 3/c 8ft 119757... BAR, support heat sink bottom 126 372 STRIP, polyest gI lam .187 x .250 x .625 140 626 STRIP, polyest gI lam .187 x .500 x 2.250 179 304 LABEL, warning exploding (CE) 153 178 LABEL, warning exploding (international) 147 386 BLOCK, term 70A 3P (international) 169 775... BRACKET, mtg terminal block (international) +128 803... BAR, support heat sink top 150 925 TRANSFORMER, current MODULE, power Fig 7-2 MODULE, diode Fig 7-2 141 515 STRIP, polyest gI lam .187 x .500 x .812 126 026 LABEL, warning electric shock can kill 179 190... LABEL, warning electric shock (CE) 119 943... STRIP, polyest gI lam .187 x .500 x 6.500 10 20 LABEL, warning general precautionary (international) LABEL, warning general precautionary (CE) 141 690... 8 18 ... 131 052 7 14 ... Assembly 164 619... CIRCUIT CARD, control (international) 178 918... CIRCUIT CARD ASSEMBLY, (CE) 6 9 ... 7-1. Main Quantity 181 156 ... 1 TRANSDUCER, current CONNECTOR & SOCKETS, (consisting of) CONNECTOR, rect skt 20-l4ga Amp 350536-1 TRANSFORMER, pwr main RESISTOR, WW fxd 30W 8K ohm RESISTOR, WW fxd 30W 200 ohm INSULATOR, flat pack SWITCH, tgl DPST 40A 600VAC 1 1 3 1 1 1 1 1 CONNECTOR & SOCKETS CONNECTOR & PINS 1 1 BLANK, snap-in nyl 1 .000mtg hole NUT, speed U type 10-32 BUSHING, snapin vyl .750 (CE) RELAY, end 24VDC DPDT CONNECTOR, clamp cable MOUNT, nprn 15/16OD PLATE, mtg bottom (CE) 1 2 1 1 .750 CASE SECTION, bottom/ends (CE) FILTER, line popwer 115/250V NAMEPLATE, (order by model and serial 1 4 1 1 1 number) 1 OM-172 200 Page 23 Dia. Item No. Mkgs. Part No. Description Figure PL1 S2-5 43 7-1. Main Assembly (Continued) 157958... LIGHT, md white lens 28V 120 376 SWITCH, rocker SPDT 4A 25OVAC 180331... LED, yellow/leads 166883... NAMEPLATE, meter 166881... BLANK, meter 097922... KNOB, pointer Quantity 1 4 1 1 nameplate backing 1 1 POTENTIOMETER, C sltd sit l/T 2W 10K ohm 151533... PANEL, front 161098... BUS BAR, output 1 C12 135286... CAPACITOR 1 ...52 C13 135289... CAPACITOR 1 ...52 C14 1 ...52 C15 141524... LEAD ASSEMBLY, elect 141525... LEAD ASSEMBLY, elect R4 C16 C17 ...52 RC7 073562... 1 1 134735... CONNECTOR w/SOCKETS, (consisting of) 134734... CONNECTOR, circ 14 pin plug Amp 213571-2 1 CONNECTOR, circ pin push-in 14-l8ga Amp 213603-1 clamp str rlf .703 max cable OD CONNECTOR, circ clamp str rlf .453 max cable OD 079739... CONNECTOR, circ Amp 206322-2 (or) 143922 1 1 141522... LEAD ASSEMBLY, elect 141523... LEAD ASSEMBLY, elect 134731 1 Amp 206070-3 CASE SECTION, bottom/rear (international) POWER CABLE, lOft (international) 1 169777 181 611 POWER CABLE, lOft 1 168755 (CE) 1 a component originally displaying a precautionary label, the label should also be ordered. Interconnecting Circuit Card PC2. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. +When ordering ++lncluded with OM-172 200 Page 24 Dia. Item No. Part No. Mkgs. Description Figure Cli 7-2. Quantity Module, Power & Diode (Fig 7-1 Item 25 & 26) CAPACITOR, polye MF .0047uf 1000V MODULE, pwr (consisting of) 247 BLADE, fan 6 in 4wg 3odeg .252 bore CCW 246 MOTOR, fan 120/230V 2600RPM w/36V sec (consisting of) 093 085... 1 2 158 540... 1 3 156 1 1 FM 4 156 RC6 BRACKET, mtg fan 146 238 5 +151 484 6 179 304 Qi-4 8 TP2 9 SRi 1 motor 1 HEATSINK,pwrmodule LABEL, warning exploding parts etc LABEL, warning exploding parts (CE) 153 178 7 1 CONNECTOR&PINS 135409 1 1 1 KIT, transistor mosfet 032 810 THERMOSTAT, NC 149 218 KIT, rectifier integ 100A 151284 CIRCUIT CARD, interconnecting 149207 PC2 PLG6 PLG11 163467 CONNECTOR&SOCKETS CONNECTOR & SOCKETS VR4 004113 VARISTOR, 12 RiO 030839 13 DM1 151479 RESISTOR, WW fxd 5W 220 ohm MODULE, diode (consisting of) 14 D5,6 151229 115092 151470 16 R9 098324 17 098325 18 C9,iO Di,2 19 TP1 129552 151431 40 4 1 1 1 1 1 joule 39OVDC 1 1 1 KIT, diode ultra fast recovery HEAT SINK, diode module 1 1 RESISTOR, WW fxd 25W 5 ohm CAPACITOR, polyp film .027uf 630V KIT, diode ultra fast recovery THERMOSTAT, NC 1 2 1 1 1 0Y Hardware is common and not available unless listed. -~9---------,~ 18 13 16 15 14 12 11 2 ST-801 588 Figure 7-2. Module, Power & Diode (175 Model Illustrated) +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-172 200 Page 25 Notes __ Notes ___ __ ___ Notes __ Notes __ __ Notes Effective January 1, 1997 (Equipment with a serial number preface of KH This limited warranty supersedes all previous Miller warranties and is exclusive with guarantees or warranties expressed or implied. * LIMITED WARRANTY below, Subject to the terms and conditions Mfg. Co., Appleton, Wisconsin, onginal retail purchaser that new Miller Miller Electric its sold after the effective date of this limited to warrants equipment Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be 1. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that 3. 2. * Replacement Parts (No labor) * Spoolmate Kits 185 Items furnished Warranty shall by Miller, nol apply but manufactured to: by others, Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. Equipment that has been modified by any party other or equipment that has been improperly which has been used for operation outside of specifications for the equipment. Years Labor the MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND main power rectifiers (input Accessory installed, Improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment International distributor. Inverters Remote Controls * than Miller, equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to the Original * such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. writing 5 Years Parts3 APT, ZIPCUT & PLAZCUT Model Plasma Cutting Millers True Bluefi Limited 2. 1. other Torches within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. an no warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR OF THE WARRANTIES INCLUDING IMPLIED, MERCHANTABILITY AND FITNESS. notified in newer) or and output rectifiers Only) PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. Parts and Labor 3 Years In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers Option: (1) repair; or (2) replacement; or, where authorized in writing by Miller In Transformer/Rectifier Power Sources Plasma Arc Power Sources Cutting Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Robots Engine Driven Welding Generators (NOTE: Engines are warranted separately by engine manufacturer.) the appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be FOB., Factory at Appleton, Wisconsin, or FOB. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. 3. Parts and Labor 1 Year Motor Driven Guns (w/exception of Spoolmate 185) Process Controllers FOR DIRECT, lNDlREC1~ SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT~ TORT OR ANY OTHER LEGAL THEORY. Positioners and Controllers Automatic Motion Devices Orbital Weld Heads IHPS Power Sources Water Coolant * HF Units * Grids Spot ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR Systems REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS MIGHT BY ARISE PROVISION, IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Welders * Load Banks * SDX Transformers * Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches PLAZCUT Models) Deutz Engines (outside (except APT, ZIPCUT & America) Options (NOTE: Field options are covered underTrue Bluefi the for remaining warranty period of the product they installed in, or for whichever is greater.) 4. 6 Months 5. 90 Days a Batteries Parts and Labor MIG Guns/TIG Torches Some states in the U.S.A. do not allow limitations of how long implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be an North Field are TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE minimum of one year available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other Ihan as staled herein, and to the extent that they may not be waived, the limitations and exclusions sel out above may not apply. This Limited Warranty provides specific legal nghts, and other rights may be available, but may vary from province to province. miIIer_warr 5/97 Owners Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment delivered to was original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Seriallstyle Number. Contact your Distributor f or: To locate distributor nearest you call 1-800-4-A-Miller. Welding Supplies Options and Consumables and Accessories Personal Safety Equipment Service and Miller Electric Repair Mfg. An Illinois Tool Wods Replacement Parts 1635 West Appleton, Training (Schools, Videos, Books) Owners and Contact the Delivering Carrier for: File USA & Canada FAX: 414-735-4134 (Servicing information a lntematk)na) FAX: 414-735-4125 European Headquarters United Kingdom Phone: 44 (0) 1625-525556 FAX: 44 (0) 1625-537553 Diagrams Welding Headquarters-USA Phone: 414-734-9821 Parts) Circuit Street WI 54914 USA International Manuals Technical Manuals Spencer Co. Company Process Handbooks claim for loss or damage during ship ment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturersTransportation Department. f//A Miller. PRINTED IN USA ' The Power ~fB1ue. 1997 Miller Electric Mfg. Co.
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