High Frequency Arc Starter - MillerWeldsHigh Frequency Arc Starter HF-20-1WG. Miller Electric...

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Processes

Description

TIG (GTAW) Welding

OM-610 029 820S

July 2002

High Frequency Arc Starter

HF-20-1WG

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit any other way.

That’s why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

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

This Owner’s Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

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

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.

CERTIFICATE

NAME OF EQUIPMENT: MODEL NO.

SERIAL NO. DATE:

This equipment has been type-tested under standardized field test conditions as recommendedby the Joint Industry Committee on High-Frequency Stabilized Arc Welding Machines found to radiateless than 10 microvolts per meter at a distance of one mile, the maximum allowable limit establishedby the Federal Communications Commission for equipment of this type.

Installations using this equipment on the basis of these tests, may reasonably be expected tomeet the radiation limitations established by the Federal Communications Commission, only wheninstalled, operated and maintained as specified in the instruction book provided.

USER’S CERTIFICATION

The welding equipment identified above has been installed in accordance with the specificinstructions applicable to this model as outlined in the instruction book furnished. It is being used onlyfor the purpose for which it was intended and is being maintained and operated in accordance with themanufacturer’s instructions

Date Installed Signed

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

TABLE OF CONTENTS

SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE1-1. Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. General Precautions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Arc Welding 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Standards Booklet Index 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS2-1. General Information And Safety 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Safety Alert Symbol And Signal Words 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS3-1. Description 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION OR RELOCATION4-1. Location 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Coolant Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Gas Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Remote Hand Switch And Receptacle Connection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Weld Input/Output Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Electrical Input Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATOR CONTROLS5-1. Process Selector Switch 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Power Switch 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. High Frequency Intensity Control 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Valve Control Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Start Selector Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Postflow Timer 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – SEQUENCE OF OPERATION6-1. Gas Tungsten Arc Welding (GTAW) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Shutting Down 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MAINTENANCE & TROUBLESHOOTING7-1. Internal Cleaning 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Interconnecting Cords 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Spark Gaps 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Tungsten Electrode 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – ELECTRICAL DIAGRAMSDiagram 8-1. Circuit Diagram For 115 Volts Models With Gas & Water Controls 22. . . . . . . . . . . . . . . Diagram 8-2. Circuit Diagram For 230 Volts Models With Gas & Water Controls 22. . . . . . . . . . . . . .

SECTION 9 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT9-1. General 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Definitions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. High-Frequency Radiation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4. Location 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5. General Installation Procedures 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6. Guidelines For Installation Of High-Frequency Assisted Arc Welding Power Sources 26. . . . . 9-7. Installation Guidelines Checklist 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – PARTS LISTFigure 10-1. Main Assembly (HF-20-WG Illustrated) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-2. HF Panel (HF-20-2WG Illustrated) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10-3. Remote Hand Switch 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF CHARTS AND TABLESTable 3-1. Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 7-1. Tungsten Size 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 7-2. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

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.)

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SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la-bels, tags, and plates on the unit pertains to equipmentdesign, installation, operation, maintenance, andtroubleshooting which should be read, understood, andfollowed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbolsfor labeling the front panel controls. The symbols alsoappear at the appropriate section in the text.

B. Safety

The installation, operation, maintenance, and trouble-shooting of arc welding equipment requires practicesand procedures which ensure personal safety and thesafety of others. Therefore, this equipment is to be in-stalled, operated, and maintained only by qualified per-sons in accordance with this manual and all applicablecodes such as, but not limited to, those listed at the endof Section 1 – Safety Rules For Operation Of Arc Weld-ing Power Source.

2-2. SAFETY ALERT SYMBOL AND SIGNALWORDS

The following safety alert symbol and signal words areused throughout this manual to call attention to andidentify different levels of hazard and special instruc-tions.

This safety alert symbol is used with the signalwords WARNING and CAUTION to call atten-tion to the safety statements.

WARNING statements identify procedures orpractices which must be followed to avoid seri-ous personal injury or loss of life.

CAUTION statements identify procedures orpractices which must be followed to avoid minorpersonal injury or damage to this equipment.

IMPORTANT statements identify special instructionsnecessary for the most efficient operation of this equip-ment.

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SECTION 3 – SPECIFICATIONS

Table 3-1. Specifications

HF-20-1WG

ModelInput

Volts AC

Rated WeldingAmps. 60%Duty Cycle Width Length Depth

Net WeightDimensions

1000 92 lbs. ( 41 kg )115 20-1/4 in.( 514 mm )

13-1/2 in.( 343 mm )

15 in.( 381 mm )

3-1. DESCRIPTION

This unit is a high-frequency arc stabilizer which super-imposes high-frequency energy on either ac or dc powersupply weld outputs. It is designed primarily for use withthe Gas Tungsten Arc Welding (GTAW) process. How-ever it can also be used for other processes requiringarc initiation and stabilization such as Submerged ArcWelding (SAW) and Plasma Arc Cutting (PAC) proc-esses.

CAUTION: HIGH-FREQUENCY ENERGYcan damage equipment.• Check with manufacturer of equipment to be

used with this unit to ensure that damage willnot occur.

Units are equipped with gas and water (coolant) valvesand a postflow timer. These units do not function proper-ly on welding power sources equipped with a primarycontactor, if the primary contactor provides on/off con-trol of the welding arc. The welding power source mustbe energized at all times for units to function properly.

SECTION 4 – INSTALLATION OR RELOCATION

4-1. LOCATION

IMPORTANT: Read entire Section 9 regarding high-frequency equipment location and installation require-ments before beginning installation.

Locate the high-frequency unit close to the work station.This will allow the electrode and work cables to be keptas short as possible, thereby minimizing high-frequencyradiation and losses.

4-2. COOLANT CONNECTIONS (Figure 4-1)

COOLANTIN

COOLANTOUT

WARNING: ELECTRIC SHOCK can kill.• Do not touch live electrical parts.

• Shut down unit and welding power source(stop and disable engine on engine drivenequipment).

• Disconnect input power employing lockout/tagging procedures before making coolantconnections.

Lockout/tagging procedures consist of remov-ing plug from receptacle, padlocking line discon-nect switch in open position, removing fusesfrom fuse box, or shutting off and red-taggingcircuit breaker or other disconnecting device.

CAUTION: OVERHEATING GAS TUNGSTENARC WELDING (GTAW) TORCH can damageunit.• Do not connect coolant hoses to the high fre-

quency unit if a recirculating coolant system isused. Make connections from the torchdirectly to the coolant system.

1. Connect a hose of suitable length and construc-tion from coolant source to the COOLANT INconnector on the front panel.

2. Connect the torch coolant hose to the COOLANTOUT connector.

Both coolant connectors have 5/8-18 in. left-handthreads.

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ST-070 989-B

WeldingPower

Work (–)

Electrode (+)

Source

Electrode

Work

Torch

AC Input Power Cord Gas In Coolant InRemote

ReceptacleWork

Figure 4-1. Interconnection Diagram

4-3. GAS CONNECTIONS (Figure 4-1)

GASIN

GASOUT



• Disconnect input power employing lockout/tagging procedures before making gas con-nections.


1. Connect a hose of suitable length and construc-tion from shielding gas supply to the GAS IN con-nector on the front panel. The gas must be con-trolled with the aid of a regulator and flowmeter.

2. Connect the torch shielding gas hose to the GASOUT connector.

Both gas connectors have 5/8-18 in. right-hand threads.

4-4. REMOTE HAND SWITCH AND RECEPTACLECONNECTION (Figure 4-1)

REMOTEA normally-closed Remote Hand Switch (with leads andplug) is supplied to provide on/off control of highfrequency, gas, and coolant. The Remote Hand Switchmust be connected to the REMOTE receptacle on the

front panel for unit to function whenever the START SE-LECTOR switch is in HIGH FREQUENCY position.

To connect switch to REMOTE receptacle, fully insertswitch plug (attached to leads) into receptacle, androtate plug fully clockwise until secure. A hose clamp(attached to switch) is supplied to secure the switch tothe torch. Install and secure switch onto torch handle indesired location.

4-5. WELD INPUT/OUTPUT CONNECTIONS (Fig-ure 4-1)

ELECTRODE WORK



• Disconnect input power employing lockout/tagging procedures before making connec-tions.


IMPORTANT: Refer to the welding power source Own-er’s Manual for proper secondary cable sizes.

Four terminals are provided on the front panel for weldinput/output connections. To make connections, pro-ceed as follows:

1. Connect welding cables from the welding powersource to the ELECTRODE and WORK termi-

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nals located on the left side of the front panel (seeFigure 4-1).

2. Connect torch cable to the ELECTRODE termi-nal and the work cable to the WORK terminal onthe right side of the front panel (see Figure 4-1).

4-6. ELECTRICAL INPUT CONNECTIONS (Fig-ures 4-1 And 4-2)

INPUT

IMPORTANT: Read and comply with entire Section 9regarding high-frequency equipment location and in-stallation requirements before making electrical inputconnections.


• Do not cut off ground terminal from plug.

• Ground in accordance with the National Elec-trical Code, state, and local codes.

CAUTION: DIRECT CURRENT (DC) willdamage the unit.• Connect unit only to alternating current (AC)

supply.

The 115 volts ac models are equipped with a 3-prongparallel plug. Connect the plug to a matching, groundedreceptacle (see Figure 4-2).

803 103

Parallel Plug On115 Volts AC Models

Figure 4-2. Electrical Input Connection Plugs

SECTION 5 – OPERATOR CONTROLS

5-1. PROCESS SELECTOR SWITCH (Figure 5-1)

DC AC

The PROCESS SELECTOR switch establishes theproper circuitry for alternating current (ac) or directcurrent (dc) welding. The switch must be placed in theAC position when the unit is connected to an ac weldingpower source or DC when connected to a dc powersource.

When the PROCESS SELECTOR switch is in the ACposition, high frequency will be present from the time anarc is initiated until the arc is broken and the postflowtimer times out.

When the PROCESS SELECTOR switch is in the DCposition, high frequency will be present only until an arcis initiated. Once an arc is established, the high frequen-cy will shut off and remain off until a restart is attempted.

5-2. POWER SWITCH (Figure 5-1)

V

POWER ON

OFF

WARNING: USING HIGH FREQUENCY WITHTHE SHIELDED METAL ARC WELDING(SMAW) PROCESS can result in seriouspersonal injury.• Place the POWER switch in the OFF position

before doing Shielded Metal Arc Welding(SMAW).

The attempted use of high frequency to estab-lish an arc with a stick electrode could cause anarc to form between the electrode holder andoperator.

Placing the POWER switch in the ON position electrical-ly energizes the unit and places it in a ready-to-weldstatus. Placing the POWER switch in the OFF positionshuts the unit down.

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ST-143 763

Welding Power SourceElectrode Connection

Welding Power SourceWork Connection Work

Connection

TorchConnection

High FrequencyIntensity Control

Remote ReceptacleAC Input

Power Cord

Gas Connections

Start Selector SwitchProcess

Selector Switch

ValveControlSwitch

PowerSwitch

CoolantConnections

Figure 5-1. Front Panel View

5-3. HIGH FREQUENCY INTENSITY CONTROL(Figure 5-1)

HF

The HIGH FREQUENCY INTENSITY control providesa means of adjusting the intensity of high-frequency en-ergy available to initiate and/or maintain an arc. Thescale surrounding the control reads from 0 to 100 andshould be used for reference only. Rotating the controlclockwise increases the intensity of the high-frequencyenergy. Normally, the control needs to be adjusted onlyinitially.

IMPORTANT: As high-frequency intensity is increased,the possibility of causing interference with local radioand television receivers also increases. Set the HIGH-FREQUENCY INTENSITY control for the lowest practi-cal setting to initiate and maintain a reliable arc andsatisfactory welding operation.

5-4. VALVE CONTROL SWITCH (Figure 5-1)

ON OFF

The VALVE CONTROL switch determines whether ornot gas and water (coolant) will be permitted to flow.When the switch is in the ON position, the gas and water(coolant) valves will function normally. When the switchis in the OFF position, the valves will remain closed.

5-5. START SELECTOR SWITCH (Figure 5-1)

A two-position switch, labeled START SELECTOR, isprovided on the front panel for selecting either TOUCHstart or HIGH FREQUENCY arc initiation.

A. TOUCH Position

When the switch is in the TOUCH position, the electrodemust be touched to the workpiece to initiate an arc.

B. HIGH FREQUENCY Position

When the switch is in the HIGH FREQUENCY position,high frequency is available to initiate an arc withouttouching the electrode to the workpiece.

IMPORTANT: When using the HIGH FREQUENCYposition of switch, the supplied normally-closed RemoteHand Switch must be connected to the REMOTE recep-tacle on the front panel (see Section 4-4). High frequen-cy is available when the Remote Hand Switch is closed.

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5-6. POSTFLOW TIMERWARNING: ELECTRIC SHOCK can kill.• Do not touch live electrical parts.


• Disconnect input power employing lockout/tagging procedures before adjusting postflowtime.


An adjustable 0 to 80 second Postflow Timer, locatedbehind the hinged access door on the rear panel, con-trols the period of time shielding gas and water (coolant)will be allowed to flow after the arc is extinguished.

To select the desired portion of the maximum 80-secondpostflow period available, rotate the knob to theappropriate setting.

SECTION 6 – SEQUENCE OF OPERATION

WARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious injury;IMPROPER AIRFLOW AND EXPOSURE TOENVIRONMENT can damage internal parts.• Do not touch live electrical parts.

• Keep all covers and panels in place whileoperating.

Warranty is void if the unit is operated with anyportion of the outer enclosure removed.

ARC RAYS, SPARKS, AND HOT SURFACEScan burn eyes and skin; NOISE can damagehearing.• Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harmyour health.• Keep your head out of the fumes.

• Ventilate to keep from breathing fumes andgases.

• If ventilation is inadequate, use approvedbreathing device.

HOT METAL, SPATTER, AND SLAG cancause fire and burns.• Watch for fire.

• Keep a fire extinguisher nearby, and knowhow to use it.

• Do not use near flammable material.

• Allow work and equipment to cool beforehandling.

MAGNETIC FIELDS FROM HIGH CUR-RENTS can affect pacemaker operation.• Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

See Section 1 - Safety Rules For Operation OfArc Welding Power Source for basic weldingsafety information.

6-1. GAS TUNGSTEN ARC WELDING (GTAW)1. Install and connect unit according to Section 4.

2. Select proper tungsten electrode (see Table 7-1).

3. Prepare tungsten electrode according to Section7-4, and insert into torch.

4. Wear dry insulating gloves and clothing.

5. Connect work clamp to clean, bare metal atworkpiece.

6. Turn on shielding gas and water (coolant) supplyat the source.

7. Energize the welding power source.

8. Place the PROCESS SELECTOR switch in thedesired position (see Section 5-1).

9. Rotate the HIGH FREQUENCY INTENSITYcontrol to the desired position (see Section 5-3).

10. Place the VALVE CONTROL switch in thedesired position (see Section 5-4).

11. Place the START SELECTOR switch in thedesired position (see Section 5-5).

12. Rotate the Postflow Timer to the desired position(see Section 5-6).

13. Wear welding helmet with proper filter lensaccording to ANSI Z49.1.

14. Place unit POWER switch in the ON position.

15. Begin welding.

6-2. SHUTTING DOWN1. Stop welding.

2. Shut down the welding power source, stop en-gine on welding generator and the high-fre-quency unit.

3. Turn off shielding gas and water (coolant) supplyat the source.

WARNING: HIGH CONCENTRATION OFSHIELDING GAS can harm health or kill.• Shut off gas supply when not in use.

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SECTION 7 – MAINTENANCE & TROUBLESHOOTING

IMPORTANT: Every six months inspect the labels onthis unit for legibility. All precautionary labels must bemaintained in a clearly readable state and replacedwhen necessary. See Parts List for part number ofprecautionary labels.

7-1. INTERNAL CLEANING



• Disconnect input power employing lockout/tagging procedures before inspecting, main-taining, or servicing.


Annually blow out or vacuum dust and dirt from aroundhigh-frequency unit internal components. If dirty ordusty conditions are present, clean unit monthly. If usingcompressed air, be sure it is clean and dry.

7-2. INTERCONNECTING CORDS





Every three months inspect all interconnecting cords fordamage to or breaks in the insulation jacket, particularlyat the plugs. Repair or replace the cord(s) as necessary.

7-3. SPARK GAPS (Figure 7-1)

It is necessary to readjust the spark gaps every three tofour months or when intermittent operation occurs. Nor-mal spark gap setting is 0.008 in. (0.203 mm).

IMPORTANT: Spark gaps widen with normal operation.At regular inspections, check and maintain the 0.008inch (0.203 mm) spark air gap to ensure consistentwelding results and compliance with FCC radiationregulations.

C

B

C

B

A

ARef. 802745

A

Figure 7-1. Spark Gap Adjustment

IMPORTANT: Do not clean or dress points since thematerial at the tips is tungsten and impossible to file.The entire point(s) (B) should be replaced when thetungsten section has completely disappeared.

The spark gap assembly is located behind an accessdoor on the rear of the unit. To adjust spark gaps,proceed as follows:





To adjust spark gaps, proceed as follows:

1. Open rear panel access door.

2. Loosen screws (A) on both sides.

3. Place feeler gauge of proper thickness betweengaps (C).

4. Apply slight pressure against points (B) so feelergauge is held firmly in gap.

5. Tighten screws (A) to 12 in/lbs torque (overtigh-tening will deform plastic base).

6. Close and secure rear panel access door.

7-4. TUNGSTEN ELECTRODE (Table 7-1 And Fig-ures 7-2 And 7-3)

Use Table 7-1 to select the correct size and type tung-sten electrode. Prepare the tungsten electrode usingthe following guidelines. A properly prepared tungstenelectrode is essential in obtaining a satisfactory weld.

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Table 7-1. Tungsten Size

Electrode Diameter

Pure Tungsten

.010”

.020”

.040”1/16”3/32”1/8”

5/32”3/16”1/4”

2% Thorium Alloyed Tungsten

.010”

.020”

.040”1/16”3/32”1/8”

5/32”3/16”1/4”

Zirconium AlloyedTungsten

.010”

.020”

.040”1/16”3/32”1/8”

5/32”3/16”1/4”

Amperage Range - Polarity - Gas Type

DC-Argon ElectrodeNegative/Straight Polarity

Up to 155-2015-80

70-150125-225225-360360-450450-720720-950

Up to 2515-4025-85

50-160135-235250-400400-500500-750750-1000

DC-Argon ElectrodePositive/Reverse Polarity

***

10-2015-3025-4040-5555-80

80-125

***

10-2015-3025-4040-5555-80

80-125

*********

*********

AC-Argon UsingHigh Frequency

Up to 155-2010-60

50-100100-160150-210200-275250-350325-450

Up to 2015-3520-80

50-150130-250225-360300-450400-500600-800

Up to 2015-3520-80

50-150130-250225-360300-450400-550600-800

AC-Argon BalancedWave Using High Freq.

Up to 1010-2020-3030-80

60-130100-180160-240190-300250-400

Up to 155-2020-60

60-120100-180160-250200-320290-390340-525

Up to 155-2020-60

60-120100-180160-250200-320290-390340-525

*NOT RECOMMENDEDThe figures listed are intended as a guide and are a composite of recommendations from American WeldingSociety (AWS) and electrode manufacturers.

S-0009/8-88

(Green Band)

(Red Band)

(Brown Band)

A. For AC or DC Electrode Positive Welding (Fig-ure 7-2)

Ball the end of tungsten electrodes used for ac or dcelectrode positive welding before beginning the weldingoperation. Weld amperage causes the tungsten elec-trode to form the balled end. The diameter of the endshould not exceed the diameter of the tungsten elec-trode by more than 1-1/2 times. For example, the end ofa 1/8 in. (3.2 mm) diameter tungsten electrode shouldnot exceed a 3/16 in. (4.8 mm) diameter end.

1-1/2 TimesElectrodeDiameter

AC And DCElectrode Positive

2-1/2 TimesElectrodeDiameter

DC ElectrodeNegative

S-0161

Figure 7-2. Properly Prepared TungstenElectrodes

OM-610 Page 20

B. For DC Electrode Negative Welding (Figures 7-2And 7-3)

CAUTION: HOT FLYING METAL PARTICLEScan injure personnel, start fires, and dam-age equipment; TUNGSTEN CONTAMINA-TION can lower weld quality.• Grinding the tungsten electrode produces

dust and flying sparks which can cause injuryand start fires. Use local exhaust (forced ven-tilation) at the grinder or wear an approvedrespirator. Read MSDS for safety informa-tion. Consider using tungsten containing cer-ia, lanthana, or yttria instead of thoria. Grind-ing dust from thoriated electrodes containslow-level radioactive material. Properly dis-pose of grinder dust in an environmentallysafe way. Wear proper face, hand, and bodyprotection. Keep flammables away.

• Shape tungsten electrode only on grinderwith proper guards in a safe location wearingproper face, hand, and body protection.

• Do not use same wheel for any other job, orthe tungsten will become contaminated.

• Shape tungsten electrodes on a fine grit, hardabrasive wheel used only for tungsten shap-ing. Grind tungsten electrodes so that grind-ing marks run lengthwise with the electrode.These procedures reduce the possibility ofthe tungsten electrode transferring foreignmatter into the weld and help reduce arc wan-der and instability at lower currents.

Stable Arc

Straight Ground

Flat(The Dia. Of This

Flat GovernsAmperage Capacity)

Arc Wander

Point

Radial Ground

TUNGSTEN PREPARATION: IDEAL

TUNGSTEN PREPARATION: WRONG

S-0162

Figure 7-3. Tungsten Preparation

Grind the end of the tungsten electrode to a taper for adistance of 2 to 2-1/2 electrode diameters in length. Forexample, the ground surface for a 1/8 in. (3.2 mm) di-ameter tungsten electrode should be 1/4 to 5/16 in. (6.4to 8.0 mm) long.

For additional information, see your distributor for ahandbook on the Gas Tungsten Arc Welding (GTAW)process.

7-5. TROUBLESHOOTING (Table 7-2)





MOVING PARTS can cause serious injury.• Keep away from moving parts.

HOT SURFACES can cause severe burns.• Allow cooling period before servicing.

Troubleshooting to be performed only byqualified persons.

It is assumed that the unit was properly installed accord-ing to Section 4 of this manual, the operator is familiarwith the function of controls, the high-frequency unit wasworking properly, and that the trouble is not related tothe welding process.

The following table is designed to diagnose and provideremedies for some of the troubles that may develop inthis high-frequency unit.

Use this table in conjunction with the circuit diagramwhile performing troubleshooting procedures. If thetrouble is not remedied after performing these proce-dures, contact the nearest Factory Authorized ServiceStation/Service Distributor. In all cases of equipmentmalfunction, the manufacturer’s recommendationsshould be strictly followed.

OM-610 Page 21

Table 7-2. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Unit completely inoper- Input power cord plug not secure in Secure power cord plug in receptacle.ative. receptacle.

Lack of high frequency; START SELECTOR switch in HIGH Place START SELECTOR switch in TOUCHdifficulty in establishing FREQUENCY position with no Remote position and touch electrode to workpiece, oran arc. Hand Switch connected to REMOTE connect Remote Hand Switch to REMOTE

receptacle on front panel. receptacle (see Sections 4-4 and 5-5).

HIGH FREQUENCY INTENSITY Increase setting of HIGH FREQUENCY control R3 setting too low or control INTENSITY Control (see Section 5-3). inoperative. Replace R3 if necessary.

Dissipation of high frequency from Be sure that torch and work cables are torch or work cable. not near any grounded metal.

Weld cable leakage. Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts.

Improper spark gap. Check spark gaps C and adjust if necessary(see Section 7-3).

Use of tungsten larger than recom- Use proper size tungsten for weldingmended for welding amperage. amperage (see Table 7-1).

Wandering arc - poor Use of tungsten considerably larger Use proper size tungsten (see Table 7-1).control of arc direction. than recommended.

Improperly prepared tungsten. Prepare tungsten as instructed in Section 7-4.

Gas flow rate too high. Reduce flow rate.

Tungsten electrode Water (coolant) in torch. Refer to torch parts list for part(s) oxidizing and not re- requiring replacement, and maining bright after repair torch as necessary.conclusion of weld.

Loose gas fittings on regulator or Check and tighten all gas fittings.gas line. This will draw air into the weld zone.

Insufficient postflow time. Increase postflow time of Timer TD1 (see Section 5-6).

Drafts blowing gas shield away Shield weld zone from drafts.from tungsten.

Insufficient high frequency. Increase setting of HIGH FREQUENCYINTENSITY control R3 (see Section 5-3).

Dirty filler rod or material. Use clean filler rod or material.

OM-610 Page 22

SECTION 8 – ELECTRICAL DIAGRAMS

Circuit Diagram No. SA-182 421-B

Diagram 8-1. Circuit Diagram For 115 Volts Models With Gas & Water Controls

OM-610 Page 23

SECTION 9 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT

9-1. GENERAL

The following information is necessary to make a properinstallation of the high-frequency arc welding equipmentdescribed in this instruction manual. In order to complywith Part 18 of the Rules and Regulations of the FederalCommunications Commission (FCC), the certificate inthe front of this manual must be filled in completely andsigned after the unit has been correctly installed. Thecertificate must be kept WITH THE EQUIPMENT ATALL TIMES to comply with the regulation. The manu-facturer of the equipment covered herein has conductedapproved field tests and certifies that the radiation canbe expected to be within the legal limits if the correct in-stallation procedures, as outlined, are followed. The im-portance of a correct installation cannot be overempha-sized since case histories of interference due to high-frequency stabilized arc welding equipment have shownthat in most cases, an inadequate installation was atfault. In the event that interference with authorized FCCservices occurs, the user is required to take suitablesteps to clear the situation. The Factory Service Depart-ment personnel will assist the user by supplying techni-cal information.

Instead of complying with the installation requirementsand the certification of each individual installation, theuser may elect to certify the entire plant by having aqualified engineer make a plant radiation survey. In suchcases, these instructions could serve as a guide in mini-mizing interference that might be caused by the high-frequency arc welding equipment.

Many processes and applications of processes requireopen-circuit voltages sufficient to jump from the elec-trode to the work without making direct contact. Themaximum open-circuit voltage (OCV) of a weldingpower source is not sufficient for this. In the SubmergedArc Welding (SAW) process, granules of flux often getbetween the electrode and the workpiece making start-ing of the arc difficult at normal open-circuit voltages. Ahigher voltage is also required to start and maintain astable arc in processes like the Gas Tungsten Arc Weld-ing (GTAW) process. In these cases it will take severalthousand volts to cause an electrical spark to jump thisgap between the electrode and the work, creating an in-itial path of ionization that the arc current can followwithout the hazards that would be present at power fre-quency.

In order to provide these higher voltages, it is commonpractice to superimpose a high open-circuit voltage onthe output of a welding power source by using high-fre-quency techniques. The high-frequency voltage can bea source of interference and will be discussed in thissection.

9-2. DEFINITIONS

A. High-Frequency Assisted Arc Welding PowerSources

In the arc welding process, high frequency may be usedfor initiating an arc or stabilizing the arc once it is struck,or for both functions.

The energy from the high-frequency source must flow tothe welding electrode via a good quality, low impedance,and well insulated connecting cable.

B. Welding Circuit

The welding circuit consists of all attachments con-nected to the welding terminals.

C. Welding Terminals

Welding terminals are the terminals which provide weld-ing power and high-frequency energy to the arc.

D. Electrode Terminal

The electrode terminal is the terminal to which the elec-trode cable or welding torch is connected.

E. Welding Torch

A device used in the Gas Tungsten Arc Welding (GTAW)process to control the position of the electrode, to trans-fer current to the arc, and to direct the flow of shieldinggas.

F. Work Terminal

The work terminal is the terminal to which the weldingworkpiece is connected.

G. Welding Zone

The welding zone is the space within 50 ft. (15 m) in alldirections from the midpoint between the power sourceand the welding arc (see Figure 9-6).

H. Bonding

Bonding refers to connecting metallic objects togetherto cause the objects to be at the same potential regard-less of any current flow between them (see Figures 9-3and 9-4).

I. Grounding (Earthing)

Depending on the practices within jurisdictions, one ofthese terms is commonly used to indicate the connec-tion, or bonding, of parts of the apparatus to theearth.The terms may be used interchangeably.

J. Receiver

A receiver is any device normally used for receivingelectromagnetic energy and converting it to useful com-munications purposes.

K. Conduction

Conduction is the transmission of high-frequency en-ergy via an electrical conductor or conducting medium.

OM-610 Page 24

L. High Frequency

High frequency is radio frequency energy, either con-tinuous or pulsed, used to start or stabilize a welding arc.

M. High-Frequency Assisted Arc Welding

High-frequency assisted arc welding refers to any of thearc welding processes requiring high frequency.

N. Interference

Interference is the unwanted and problematic receptionof high-frequency energy.

O. Radiation

Radiation is the transmission of high-frequency energythrough space.

9-3. HIGH-FREQUENCY RADIATION

Installations using high frequency, either as an integralpart of the power source or as an accessory unit, willproduce some high-frequency radiation. Such radiation,if the signal strength is sufficient at the receiving device,can cause an inconvenience or disruption of communi-cations or can cause malfunction in sensitive electroniccontrols and systems. The four major causes of high-frequency radiation are as follows:

A. Direct Radiation From The Power Source OrHigh-Frequency Accessory Unit

Direct radiation is that radiation emanating directly fromthe power source or accessory unit. Radiation from thepower line and welding power source accessories is notconsidered to be direct radiation from the power sourceor accessory unit.

B. Direct Radiation From The Welding Circuit

Any attachment to the output terminals of the high-fre-quency source is capable of acting as an antenna andradiating high-frequency energy. Attachments includeweld cables, torches, worktables, etc. Since direct ra-diation from the welding circuit is the major source of ra-diation, it is important to keep attachments to a mini-mum.

C. Conduction And Radiation From The PowerLine

Most power lines are capable of conducting high-fre-quency energy which may cause interference directly orby reradiation from these power lines. Normally such ra-diation is small when compared to that caused by radia-tion from the weld cables.

D. Reradiation

Radiation from the welding circuit can be picked up byungrounded metal objects or unshielded wiring in theimmediate vicinity, conducted some distance, andreradiated. This can be a troublesome source of inter-ference.

9-4. LOCATION

Locate the high-frequency power source as close to thewelding process as possible. Also consider the near-ness of a suitable ground connection when selecting asite for the installation of the power source. Ideally, thehigh-frequency power source should be located in anarea where there is a limited amount of miscellaneouswiring (lighting, power, telephone, communications, andother unshielded conductors) located within the weldingzone. Ungrounded, metallic conductors in the weldingzone can act as antennas which will pick up, conduct, orreradiate the high-frequency energy transmitted by thewelding circuit. All miscellaneous wiring in the weldingzone should be enclosed in grounded, rigid metallic con-duit, copper braid, or some other material having anequivalent shielding efficiency, and grounded at 50 ft.(15 m) intervals (see Figure 9-1).

S-0017

High-FrequencyWelding

Power Source

Shielded Wire

Ground At 50ft.(15 m) Intervals

50 ft.(15 m)

Work Clamp

Ground

Keep all unshielded and ungroundedwires out of the welding zone.

HolderElectrode

Figure 9-1. Requirements To Minimize Reradia-tion Pickup In The Vicinity Of The Welding Zone

9-5. GENERAL INSTALLATION PROCEDURES

A. Weld Cables

Keep the weld cables as short as possible and do notexceed 25 ft. (8 m) in length. Position the cables asclose together and as close to the floor or ground planeas possible.

If the welding operation must be carried out at a pointfarther than 25 ft. (8 m) from the welding power source,use a portable high-frequency source and locate theportable unit within 25 ft. (8 m) of the welding electrode.

B. High-Frequency Assisted Arc Welding PowerSources

When the high-frequency assisted arc welding powersource is in operation, all service doors and covers mustbe closed, securely fastened, and adequately bonded toensure good contact around the entire perimeter of theopening. Except for changes and adjustments allowedby the manufacturer, the high-frequency assisted arcwelding power source should not be modified.

OM-610 Page 25

S-0018

High-FrequencyWelding Power Source

Electrode

Place leads on floor or on boardsand keep 3/4 in. (19 mm)

to 1 in. (25 mm) apart.

ElectricalInput

SupplyGround

Work Clamp

Holder

Figure 9-2. General Rules For Welding Leads

C. Grounding (Earthing) The Weld Cables

Be sure that the enclosure of the high-frequency powersource is firmly grounded to the WORK terminal. If thehigh-frequency power source is not labeled as being in-ternally high-frequency grounded, then this groundmust be made by grounding the enclosure to the WORKterminal with No. 12 AWG gauge or smaller wire. Con-nect the ground wire to a driven ground rod or to a waterpipe which enters the earth within 10 ft. (3 m) of the high-frequency power source.

D. Metal Buildings

Installation of a high-frequency power source within asuitably bonded and grounded (earthed) metal buildingcan be an effective means of reducing high-frequencyradiation. Wherever possible, install high-frequencypower sources in such places.

S-0019

GroundedCopper Screens

Metal Building

Driven

Grounding WireMetal Panels

Metal Panels

Bonding Of Metal Panels

Panels

GroundRod

Figure 9-3. Grounding And BondingPanels Of Metal Building

However, when the high-frequency power source is in-stalled within a metal building, precautions must betaken to be sure that the building is properly bonded andgrounded (earthed). This can be accomplished by plac-ing several good electrical ground rods around the pe-riphery of the building. During the construction of a newbuilding of any type having metal in the structure, besure that all the reinforcing and structural steel isbonded together (as by welding each piece of metal toall other adjacent pieces). For metal buildings, adjacentmetal panels should be bolted or welded together at fre-quent intervals.All windows and doorways should becovered with grounded copper screen or galvanizedhardware cloth of not more than 1/4 in. (6.4 mm) mesh.

E. Shielding Of Miscellaneous Wiring In The Weld-ing Zone

Ungrounded, metallic conductors in the welding zonecan act as antennas which will pick up, conduct, and/orreradiate the high-frequency energy transmitted by thewelding circuit located within or near the welding zone.This means that all ungrounded water pipes must begrounded, and that all lighting, power, telephone, com-munications, and other conductors within the weldingzone must be enclosed in grounded, rigid metallic con-duit, copper braid, or some other material having anequivalent shielding capability (spirally wound, flexible,metallic conduit is not suitable). Shielding of the miscel-laneous wiring in the welding zone must be grounded at50 ft. (15 m) intervals. Excellent low resistance electricalconnections must be maintained between conduit sec-tions (see Figure 9-4).

S-0020

Copper Strap

Figure 9-4. Bonding Method For Poor Conductors

F. Power Service

The high-frequency power source should be connectedto the line input power supply as instructed in this man-ual. If the unit is equipped with a power cord, the supplyconductors serving the high-frequency power sourceshould be completely enclosed in solid metallic conduit,or in equivalent shielding, up to the point of connectionwith the power cord. The solid, metallic conduit, orequivalent shielding, should extend the entire distancefrom the power entrance location in the building to thehigh-frequency power source. Shielding should be elec-trically continuous throughout its length and should beconnected so that good electrical contact is provided be-tween the shield and the high-frequency power source.

OM-610 Page 26

S-0021

Line Input

50 ft. (15 m)

Power Supply

Solid Metallic Conduit

Line Fuse And Switch BoxGround

High-FrequencyWelding Power Source

Or Receptacle

Figure 9-5. Installation Of High-FrequencyStabilized Arc Welding Power Source

9-6. GUIDELINES FOR INSTALLATION OF HIGH-FREQUENCY ASSISTED ARC WELDINGPOWER SOURCES

7. Locate the equipment so that the ground wire ofthe high-frequency power source can be kept asshort as possible.

8. Shield the line input power leads up to the point ofconnection with the enclosure of the high-fre-quency power source as specified by the manu-facture’s requirements (see Section 9-5F).

9. Be sure that there is good electrical contact madeat the enclosure of the high-frequency weldingpower source, through the conduit, and back tothe service box. Be sure that the conduit systemis continuous to a point at least 50 ft. (15 m) fromthe equipment, and that the conduit system isone complete run within the high-frequency zone.If rigid, metallic conduit is not used, be sure thatthe shielding used has equivalent shielding effi-ciency. Copper sleeving, lead covered cable, orthe equivalent, is satisfactory. Spirally wound,flexible, metallic conduit is not suitable.

10. Keep WORK and ELECTRODE cables as shortand straight as possible.

11. Keep weld cables to a maximum length of 25 ft. (8m).

12. Keep weld cables as close together and as closeto the ground plane as possible.

13. Adjust spark gap setting to the minimum settinggiven in this manual.

14. Secure all service and access doors before oper-ating.

15. Visualize the welding zone as a sphere with a 50ft. (15 m) radius centered on a point between thepower source and the electrode holder (see Fig-ure 9-6), and proceed as follows:

a. Have all unshielded power, lighting, and com-munication wires within the welding zoneplaced in grounded shields or relocated outsidethe welding zone.

b. Ground all large metallic objects, long guywires, or support wires within the welding zone.

c. Be sure that there are no external power or tele-phone wires, which may be off the immediatepremises, within the welding zone.

S-0022Center Point

High-Frequency

ElectrodeHolder

SourceWelding Power

Figure 9-6. Welding Zone

16. Use driven ground rods which enter the ground10 ft. (3 m) or less from the ground connection, orcold water pipes, as the ground for the high-fre-quency welding power source.

17. Be sure that all ground connections are clean andtight.

18. If the high-frequency welding power source is op-erated within a metal building, be sure that thebuilding is properly grounded.

9-7. INSTALLATION GUIDELINES CHECKLIST

All items may not be necessary or practical for each in-stallation. Complete the necessary items to eliminate in-terference with authorized FCC services.

1. Is equipment properly located?(See Sections 9-4, 9-5D, 9-5E, 9-6.1, and 9-6.9.)

2. Are ac input power connections properly made?(See Sections 9-5B, 9-6.2, and 9-6.3.)

3. Are weld cables and equipment properly in-stalled?(See Sections 9-5A, 9-6.4, 9-6.5, and 9-6.6.)

4. Are ground connections properly made?(See Sections 9-5C, 9-6.1, 9-6.6, 9-6.11, and9-6.12.)

5. Is equipment properly set up and adjusted?(See Sections 9-6.7 and 9-6.8.)

OM-610 Page 27

Notes

OM-610 Page 28

SECTION 10 – PARTS LIST

SD-143 760-B

1

2

3

4

56

7

8 9

10

11

12

13 F

ig 1

0–2

14

15

16

1718

19

2021

22

23

24 25

2627

2829

30313233

Figure 10-1. Main Assembly

OM-610 Page 29

Description QuantityPartNo.

Dia.Mkgs.

Figure 10-1. Main Assembly

ItemNo.

1 139 749 TERMINAL BOARD, pwr input/output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 048 427 BUS BAR, output 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 048 426 BUS BAR, secondary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T2 186 623 COIL, coupling air HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 131 515 LABEL, warning electric shock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 +048 431 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 602 261 HANDLE, chest 3-1/2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 601 795 BOLT, mach stl hexhd .250-20 x 4.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 010 853 FASTENER, screw sltd hd No. 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 010 855 RETAINER, screw No. 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 010 854 NUT, speed No. 2 clip-on type 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 142 795 CASE SECTION, base/front/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 141 736 HF PANEL, (Fig 10-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 010 006 TUBING, stl .625 OD x 12ga wall x 3.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 178 862 PANEL, mtg door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 160 929 COVER, stud output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 605 787 WASHER, lock stl intl tooth .500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 601 879 NUT, stl hex full fnsh .500-13 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 601 976 SCREW, cap stl hexhd .500-13 x 1.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 C1 141 204 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 S1,3 011 611 SWITCH, tgl DPDT 15A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 S2,4 011 609 SWITCH, tgl SPDT 15A 125VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 R3 198 547 RHEOSTAT, WW 25W 1.5 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 602 221 WASHER, lock stl intl tooth .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 RC1 201 467 RECEPTACLE, twlk 2P2W 20A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 618 PLUG, twlk 2P2W 20A 250V Arrow Hart 9102N. . . . . . . . . . . . . . . . . . . 26 NAMEPLATE, (order by model and style number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 097 922 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 605 321 NUT, stl hex .468-32 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PLG1 192 457 CORD SET, pwr 115V 16ga 3/c 11ft 5 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 139 042 BUSHING, strain relief .270/.480 ID x .804mtg hole, P/O cordset 1. . . . . . . . . . . . . . . . . . . . . . . . 31 GS1,WS1 003 538 VALVE, 115VAC 2way 1/4 IPS port 1/8 orf out 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 010 295 FITTING, pipe brs elb M 1/4NPT x .625-18LH 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 010 296 FITTING, pipe brs elb M 1/4NPT x .625-18RH 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 10-3 REMOTE HAND SWITCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-610 Page 30


Dia.Mkgs.

Figure 10-2. HF Panel (Fig 10-1 Item 13)

ItemNo.

1 G 204 480 SPARK GAP ASSEMBLY (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 855 BASE, spark gap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 856 HOLDER, points 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 455 POINTS, spark gap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 141 735 MOUNTING BOARD, component HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 T3 098 337 TRANSFORMER (Part of discontinued HF-20-2WG model). . . . . . . . . . . . . . 4 T1 208 045 TRANSFORMER, high voltage 115V Pri 3600V Sec mA w/term 1. . . . . . . . . . . . . . . . . . . . . . 5 C3 191 944 CAPACITOR, polyp film 10uf 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 R2 030 603 RESISTOR, WW fxd 10W 10K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TD1 114 494 TIMER, delay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 R5 030 686 POTENTIOMETER, cp std 1/T 2W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 182 294 BRACKET, mtg pot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 097 922 KNOB 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 R4 030 601 RESISTOR, WW adj 25W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 R1 083 784 RESISTOR, WW fxd 100W 10 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C2 096 761 CAPACITOR, mica .002uf 10000V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C5 031 630 CAPACITOR, elctlt 22uf 50VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C6 046 140 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CR2 059 266 RELAY, encl 120VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CR1 059 267 RELAY, encl 12VDC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*206 502 SERVICE KIT, spark gap assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-143 761-D

1 2

3

4

5

6

7

89

10

11

12

13

14

15

16

17

18

Figure 10-2. HF Panel

*Recommended Spare Parts.BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-610 Page 31


Figure 10-3. Remote Hand Switch

ItemNo.

Dia.Mkgs.

1 039 618 PLUG, twlk 2P2W 20A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 600 340 CABLE, port No. 16 2/c (order by ft) 20ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 070 585 TUBING, gl acrylic .162-.178 ID (order by ft) 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RHS-11A 011 752 SWITCH, slide NC (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 010 860 CLAMP, hose .812-1.750clp dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SA-143 762

1

2

3

45

Figure 10-3. Remote Hand Switch

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Warranty Questions?

Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 6/02

Your distributor also givesyou ...

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

Effective January 1, 2002(Equipment with a serial number preface of “LC” or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY – Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrantsto its original retail purchaser that new Miller equipment soldafter the effective date of this limited warranty is free of defectsin material and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair orreplace any warranted parts or components that fail due tosuch defects in material or workmanship. Miller must benotified in writing within thirty (30) days of such defect orfailure, at which time Miller will provide instructions on thewarranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date thatthe equipment was delivered to the original retail purchaser, orone year after the equipment is sent to a North Americandistributor or eighteen months after the equipment is sent to anInternational distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources* Plasma Arc Cutting Power Sources* Semi-Automatic and Automatic Wire Feeders* Inverter Power Supplies* Intellitig* Engine Driven Welding Generators

(NOTE: Engines are warranted separately bythe engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)* Process Controllers* Positioners and Controllers* Automatic Motion Devices* RFCS Foot Controls* Induction Heating Power Sources* Water Coolant Systems* Flowgauge and Flowmeter Regulators (No Labor)* HF Units* Grids* Maxstar 85, 140* Spot Welders* Load Banks* Racks* Running Gear/Trailers* Plasma Cutting Torches (except APT & SAF

Models)* Field Options

(NOTE: Field options are covered under TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma CuttingTorches

* Remote Controls* Accessory Kits

* Replacement Parts (No labor)* Spoolmate Spoolguns* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, slip rings,relays or parts that fail due to normal wear.(Exception: brushes, slip rings, and relays arecovered on Bobcat, Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others,such as engines or trade accessories. These items arecovered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party otherthan Miller, or equipment that has been improperlyinstalled, improperly operated or misused based uponindustry standards, or equipment which has not hadreasonable and necessary maintenance, or equipmentwhich has been used for operation outside of thespecifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASEAND USE BY COMMERCIAL/INDUSTRIAL USERS ANDPERSONS TRAINED AND EXPERIENCED IN THE USEAND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Miller’s option: (1) repair; or (2)replacement; or, where authorized in writing by Miller inappropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Miller service station; or (4)payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goodsat customer’s risk and expense. Miller’s option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Miller authorized service facility as determined byMiller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT ORANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREINAND ANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THISPROVISION, MIGHT ARISE BY IMPLICATION,OPERATION OF LAW, CUSTOM OF TRADE OR COURSEOF DEALING, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALLEQUIPMENT FURNISHED BY MILLER IS EXCLUDED ANDDISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how longan implied warranty lasts, or the exclusion of incidental,indirect, special or consequential damages, so the abovelimitation or exclusion may not apply to you. This warrantyprovides specific legal rights, and other rights may beavailable, but may vary from state to state.

In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein,and to the extent that they may not be waived, the limitationsand exclusions set out above may not apply. This LimitedWarranty provides specific legal rights, and other rights maybe available, but may vary from province to province.

PRINTED IN USA 2002 Miller Electric Mfg. Co. 5/02

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125

European Headquarters –United KingdomPhone: 44 (0) 1204-593493FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Call 1-800-4-A-Miller or see our website at www.MillerWelds.comto locate a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Informationand Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier for:

For assistance in filing or settling claims,contact your distributor and/or equipmentmanufacturer’s Transportation Department.

For Service

Owner’s Record

File a claim for loss or damage duringshipment.

Contact your Distributor for:

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