Maxstar 300 DX - Miller - Welding Equipment - MIG/TIG/Stick … · 2015-05-21 · Miller Electric...

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Transcript of Maxstar 300 DX - Miller - Welding Equipment - MIG/TIG/Stick … · 2015-05-21 · Miller Electric...

  • And Non-CE Models

    Processes

    Description

    TIG (GTAW) Welding

    Stick (SMAW) Welding

    Arc Welding Power Source

    OM-2222 189533CAugust 1999

    Maxstar 300 DX

    230/460 Volt Models W/Autolink

    400 Volts Models

    Visit our website at

    www.MillerWelds.com

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

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

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

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

    This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. They willhelp you protect yourself against potential hazards on the worksite. Weve

    made installation and operation quick and easy.With Miller you can count on years of reliableservice with proper maintenance. And if forsome reason the unit needs repair, theres aTroubleshooting section that will help youfigure out what the problem is. The parts listwill then help you to decide which exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also provided.

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

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

    From Miller to You

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

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

    TABLE OF CONTENTS

    SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

    et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

    SECTION 4 OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Description Of Controls (Use With Sections A And B) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Remote Trigger (Normal) Mode 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Remote Trigger (2T) Hold Mode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. 4T (Specific Trigger Method) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Reconfiguring 4T For Mini Logic Control, Spot, Contactor On, Or Lift-Arc 26. . . . . . . . . . . . . . . 4-7. Mini Logic Operation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Spot Control Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Contactor On Lift-Arc Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Lift-ArcE And HF TIG Start Procedures 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Programmable HF Start Amperage And Time Modes 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Arc Timer/Counter Display 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13. Lock Out Functions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 5 MAINTENANCE AND TROUBLESHOOTING 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Blowing Out Inside Of Unit 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Voltmeter/Ammeter Help Displays 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Troubleshooting 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

    SECTION 10 PARTS LIST 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY

    OM-2222C

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

  • dec_con1 10/95

    Declaration of Conformity ForEuropean Community (CE) Products

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

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

    Appleton, WI 54914 USA

    Declares that the product: Maxstar 300 DXconforms to the following Directives and Standards:

    Directives

    Low Voltage Directive: 73/23/EEC

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

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

    Standards

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

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

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

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

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

    European Contact: Mr. Luigi Vacchini, Managing DirectorMILLER Europe S.P.A.Via Privata Iseo20098 San GiulianoMilanese, Italy

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

  • OM-2222 Page 1

    SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_5/97

    1-1. Symbol Usage

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

    Marks a special safety message.

    Means Note; not safety related.

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

    1-2. Arc Welding Hazards

    The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-4. Read andfollow all Safety Standards.

    Only qualified persons should install, operate, maintain, andrepair this unit.

    During operation, keep everybody, especially children, away.

    ELECTRIC SHOCK can kill.

    Touching live electrical parts can cause fatalshocks or severe burns. The electrode and workcircuit 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 orautomatic wire welding, the wire, wire reel, drive roll housing, and allmetal parts touching the welding wire are electrically live. Incorrectlyinstalled or improperly grounded equipment is a hazard.

    Do not touch live electrical parts.

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

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

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

    Use AC output ONLY if required for the welding process.

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

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

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

    Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminalin disconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

    When making input connections, attach proper groundingconductor first double-check connections.

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

    Turn off all equipment when not in use.

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

    Do not drape cables over your body.

    If earth grounding of the workpiece is required, ground it directlywith a separate cable do not use work clamp or work cable.

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

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

    Wear a safety harness if working above floor level.

    Keep all panels and covers securely in place.

    Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.

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

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

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

    capacitors according to instructions in Maintenance Sectionbefore touching any parts.

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

    FUMES AND GASES can be hazardous.

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

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

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

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

    Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure thebreathing air is safe.

    Do not weld in locations near degreasing, cleaning, or sprayingoperations. The heat and rays of the arc can react with vapors toform highly toxic and irritating gases.

    Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from theweld area, the area is well ventilated, and if necessary, whilewearing an air-supplied respirator. The coatings and any metalscontaining these elements can give off toxic fumes if welded.

  • OM-2222 Page 2

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

    ARC RAYS can burn eyes and skin.

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

    Wear approved safety glasses with side shields under yourhelmet.

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

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

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

    and burns. Accidental contact of electrode to metal objects cancause sparks, explosion, overheating, or fire. Check and be sure thearea is safe before doing any welding.

    WELDING can cause fire or explosion.

    Protect yourself and others from flying sparks and hot metal.

    Do not weld where flying sparks can strike flammable material.

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

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

    Watch for fire, and keep a fire extinguisher nearby.

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

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

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

    Do not use welder to thaw frozen pipes.

    Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

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

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

    FLYING METAL can injure eyes.

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

    Wear approved safety glasses with sideshields even under your welding helmet.

    BUILDUP OF GAS can injure or kill.

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

    approved air-supplied respirator.

    HOT PARTS can cause severe burns.

    Do not touch hot parts bare handed. Allow cooling period before working on gun or

    torch.

    MAGNETIC FIELDS can affect pacemakers.

    Pacemaker wearers keep away. Wearers should consult their doctor before

    going near arc welding, gouging, or spotwelding operations.

    NOISE can damage hearing.

    Noise from some processes or equipment candamage hearing.

    Wear approved ear protection if noise level ishigh.

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

    CYLINDERS can explode if damaged.

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

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

    Keep cylinders away from any welding or other electrical circuits.

    Never drape a welding torch over a gas cylinder.

    Never allow a welding electrode to touch any cylinder.

    Never weld on a pressurized cylinder explosion will result.

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

    Turn face away from valve outlet when opening cylinder valve.

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

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

  • OM-2222 Page 3

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

    FIRE OR EXPLOSION hazard.

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

    Do not install unit near flammables.

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

    FALLING UNIT can cause injury.

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

    Use equipment of adequate capacity to lift andsupport unit.

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

    OVERUSE can cause OVERHEATING

    Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before

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

    STATIC (ESD) can damage PC boards.

    Put on grounded wrist strap BEFOREhandling boards or parts.

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

    MOVING PARTS can cause injury.

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

    rolls.

    WELDING WIRE can cause injury.

    Do not press gun trigger until instructed to doso.

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

    MOVING PARTS can cause injury.

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

    closed and securely in place.

    H.F. RADIATION can cause interference.

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

    Have only qualified persons familiar withelectronic equipment perform this installation.

    The user is responsible for having a qualified electricianpromptly correct any interference problem resulting from theinstallation.

    If notified by the FCC about interference, stop using theequipment at once.

    Have the installation regularly checked and maintained.

    Keep high-frequency source doors and panels tightly shut,keep spark gaps at correct setting, and use grounding andshielding to minimize the possibility of interference.

    ARC WELDING can cause interference.

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

    Be sure all equipment in the welding area iselectromagnetically compatible.

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

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

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

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

    1-4. Principal Safety Standards

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

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

  • OM-2222 Page 4

    1-5. EMF Information

    Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

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

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

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

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

    5. Connect work clamp to workpiece as close to the weld aspossible.

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

  • OM-2222 Page 5

    SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATIONsom _nd_fre 5/97

    1-1. Signification des symboles

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

    Identifie un message de scurit particulier.

    Signifie NOTA ; nest pas relatif la scurit.

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

    1-2. Dangers relatifs au soudage larc

    Les symboles prsents ci-aprs sont utiliss tout au long duprsent manuel pour attirer votre attention et identifier lesrisques de danger. Lorsque vous voyez un symbole, soyezvigilant et suivez les directives mentionnes afin dviter toutdanger. Les consignes de scurit prsentes ci-aprs ne fontque rsumer linformation contenue dans les normes de scuritnumres la section 1-4. Veuillez lire et respecter toutes cesnormes de scurit.

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

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

    UN CHOC LECTRIQUE peut tuer.

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

    tension ce moment-l. En soudage semi-automatique ou automatique,le fil, le dvidoir, le logement des galets dentranement et les picesmtalliques en contact avec le fil de soudage sont sous tension. Desmatriels mal installs ou mal mis la terre prsentent un danger.

    Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant

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

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

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

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

    Si lutilisation dune source lectrique courant lectrique savre nces-saire, se servir de la fonction de tlcommande si lappareil en est quip.

    Couper lalimentation ou arrter le moteur avant de procder linstal-lation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normesde scurit).

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

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

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

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

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

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

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

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

    Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel.

    Porter un harnais de scurit quand on travaille en hauteur.

    Maintenir solidement en place tous les panneaux et capots.

    Fixer le cble de retour de faon obtenir un bon contact mtal-mtalavec la pice souder ou la table de travail, le plus prs possible de lasoudure.

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

    Il y a DU COURANT CONTINU IMPORTANT dans lesconvertisseurs aprs la suppression de lalimenta-tion lectrique.

    Arrter les convertisseurs, dbrancher le courant lectrique, et d-charger les condensateurs dalimentation selon les instructionsindiques dans la partie entretien avant de toucher les pices.

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

    Eloigner votre tte des fumes. Ne pas respirerles fumes.

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

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

    Lire les spcifications de scurit des matriaux (MSDSs) et les ins-tructions du fabricant concernant les mtaux, les consommables,les revtements, les nettoyants et les dgraisseurs.

    Travailler dans un espace ferm seulement sil est bien ventil ouen portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes etdes gaz de soudage peuvent dplacer lair et abaisser le niveaudoxygne provoquant des blessures ou des accidents mortels.Sassurer que lair de respiration ne prsente aucun danger.

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

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

    LES FUMES ET LES GAZ peuventtre dangereux.

  • OM-2222 Page 6

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

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

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

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

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

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

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

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

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

    LE SOUDAGE peut provoquer unincendie ou une explosion.

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

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

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

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

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

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

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

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

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

    En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

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

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

    DES PARTICULES VOLANTESpeuvent blesser les yeux.

    Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrentdes tincelles et des particules mtalliques volan-

    tes. Pendant la priode de refroidissement des soudures, elles risquentde projeter du laitier. Porter des lunettes de scurit avec crans latraux ou un cran facial.

    LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort.

    Fermer lalimentation du gaz protecteur en cas denon utilisation.

    Veiller toujours bien arer les espaces confins ou se servir dun respi-rateur dadduction dair homologu.

    DES PICES CHAUDES peuvent pro-voquer des brlures graves.

    Ne pas toucher des parties chaudes mainsnues

    Prvoir une priode de refroidissement avantdutiliser le pistolet ou la torche.

    LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

    Porteurs de stimulateur cardiaque, restez distance.

    Les porteurs dun stimulateur cardiaque doiventdabord consulter leur mdecin avant de sapprocherdes oprations de soudage larc, de gougeage oude soudage par points.

    LE BRUIT peut affecter loue.

    Le bruit des processus et des quipements peut affecterloue.

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

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

    manipuler avec prcaution.

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

    Placer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empcher de tomber oude se renverser.

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

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

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

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

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

    Maintenir le chapeau de protection sur la soupape, sauf en casdutilisation ou de branchement de la bouteille.

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

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

  • OM-2222 Page 7

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

    Risque DINCENDIE OUDEXPLOSION.

    Ne pas placer lappareil sur, au-dessus ou proximit de surfaces infllammables.

    Ne pas installer lappareil proximit de produits inflammables Ne pas surcharger linstallation lectrique sassurer que lalimen-

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

    LA CHUTE DE LAPPAREIL peutblesser.

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

    Utiliser un engin dune capacit approprie poursoulever lappareil.

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

    LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.

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

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

    Ne pas obstruer les passages dair du poste.

    LES CHARGES LECTROSTATIQUESpeuvent endommager les circuits im-prims.

    tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

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

    DES ORGANES MOBILES peuventprovoquer des blessures.

    Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

    tels que des rouleaux de commande.

    LES FILS DE SOUDAGE peuvent pro-voquer des blessures.

    Ne pas appuyer sur la gachette avant den avoirreu linstruction.

    Ne pas diriger le pistolet vers soi, dautres per-sonnes ou toute pice mcanique en engageantle fil de soudage.

    DES ORGANES MOBILES peuventprovoquer des blessures.

    Rester lcart des organes mobiles comme leventilateur.

    Maintenir ferms et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection.

    LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences.

    Le rayonnement haute frequence peut provoquerdes interfrences avec les quipements de ra-dionavigation et de communication, les servicesde scurit et les ordinateurs.

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

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

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

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

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

    LE SOUDAGE LARC risque deprovoquer des interfrences.

    Lnergie lectromagntique risque deprovoquer des interfrences pour lquipementlectronique sensible tel que les ordinateurs etlquipement command par ordinateur tel queles robots.

    Veiller ce que tout lquipement de la zone de soudage soit com-patible lectromagntiquement.

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

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

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

    En cas dinterfrences aprs avoir pris les mesures prcdentes, ilincombe lutilisateur de prendre des mesures supplmentairestelles que le dplacement du poste, lutilisation de cbles blinds,lutilisation de filtres de ligne ou la pose de protecteurs dans la zonede travail.

    LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

    Porteurs de stimulateur cardiaque, restez dis-tance.

    Les porteurs dun stimulateur cardiaque doiventdabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.

  • OM-2222 Page 8

    1-4. Principales normes de scurit

    Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Wel-ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

    Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402.

    Recommended Safe Practice for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, normeAWS F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Mia-mi FL 33126

    National Electrical Code, NFPA Standard 70, de la National Fire Pro-tection Association, Batterymarch Park, Quincy, MA 02269.

    Safe Handling of Compressed Gases in Cylinders, CGA PamphletP-1, de la Compressed Gas Association, 1235 Jefferson Davis High-way, Suite 501, Arlington, VA 22202.

    Rgles de scurit en soudage, coupage et procds connexes, nor-me CSA W117.2, de lAssociation canadienne de normalisation, ventede normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W1R3.

    Safe Practices For Occupation And Educational Eye And Face Protec-tion, norme ANSI Z87.1, de lAmerican National Standards Institute,1430 Broadway, New York, NY 10018.

    Cutting and Welding Processes, norme NFPA 51B, de la National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

    1-5. Information sur les champs lectromagntiques

    Donnes sur le soudage lectrique et sur les effets, pour lorganisme,des champs magntiques basse frquence

    Le courant de soudage, pendant son passage dans les cbles de sou-dage, causera des champs lectromagntiques. Il y a eu et il y aencore un certain souci propos de tels champs. Cependant, aprsavoir examin plus de 500 tudes qui ont t faites pendant une p-riode de recherche de 17 ans, un comit spcial ruban bleu duNational Research Council a conclu: Laccumulation de preuves, sui-vant le jugement du comit, na pas dmontr que lexposition auxchamps magntiques et champs lectriques haute frquence repr-sente un risque la sant humaine. Toutefois, des tudes sonttoujours en cours et les preuves continuent tre examines. En at-tendant que les conclusions finales de la recherche soient tablies, ilvous serait souhaitable de rduire votre exposition aux champs lec-tromagntiques pendant le soudage ou le coupage.

    Afin de rduire les champs lectromagntiques dans lenvironnementde travail, respecter les consignes suivantes :

    1 Garder les cbles ensembles en les torsadant ou en lesattachant avec du ruban adhsif.

    2 Mettre tous les cbles du ct oppos de loprateur.

    3 Ne pas courber pas et ne pas entourer pas les cbles autour devotre corps.

    4 Garder le poste de soudage et les cbles le plus loin possiblede vous.

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

    Consignes relatives aux stimulateurs cardiaques :

    Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur docteur. Si vous tes dclar apte par votre docteur, ilest alors recommand de respecter les consignes cidessus.

  • OM-2222 Page 9

    SECTION 2 DEFINITIONS (CE Models)

    2-1. Warning Label Definitions

    Warning! Watch Out! There arepossible hazards as shown by thesymbols.

    1 Electric shock from weldingelectrode or wiring can kill.

    1.1 Wear dry insulating gloves.Do not touch electrode withbare hand. Do not wear wetor damaged gloves.

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

    1.3 Disconnect input plug orpower before working onmachine.

    2 Breathing welding fumes canbe hazardous to your health.

    2.1 Keep your head out of thefumes.

    2.2 Use forced ventilation or localexhaust to remove the fumes.

    2.3 Use ventilating fan to removefumes.

    3 Welding sparks can causeexplosion or fire.

    3.1 Keep flammables away fromwelding. Do not weld nearflammables.

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

    3.3 Do not weld on drums or anyclosed containers.

    4 Arc rays can burn eyes andinjure skin.

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

    5 Become trained and read theinstructions before workingon the machine or welding.

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

    1/96

    1 1.1 1.2 1.3

    3 3.1 3.2 3.3

    4 4.1

    +

    2 2.1 2.2

    +

    +

    5 6

    +

    2.3

    S-179 310

  • OM-2222 Page 10

    Warning! Watch Out! There arepossible hazards as shown by thesymbols.

    1 Electric shock from wiringcan kill.

    2 Disconnect input plug orpower before working onmachine.

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

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

    5 Check input capacitorvoltage, and be sure it is near0 before touching any parts.

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

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

    8 Always wear long sleevesand button your collar whenservicing unit.

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

    S-185 836

    > 60 s

    VV

    V

    1 2 3 4 5

    6 7 8 9

    S-179 309-A

    =

  • OM-2222 Page 11

    2-2. Manufacturers Rating Label For CE Products

    ST-188 153-A

    For label locationsee Section 3-4.

  • OM-2222 Page 12

    2-3. Symbols And Definitions

    A Amperes PanelLocal Gas Tungsten ArcWelding (GTAW) Shielded Metal ArcWelding (SMAW)

    V Volts Input 3 Phase Static FrequencyConverter-Transformer-RectifierOutput Circuit Breaker Remote

    Touch Start(GTAW)

    Protective Earth(Ground) Postflow Timer Preflow Timer S Seconds

    On Off Positive Negative

    AlternatingCurrent Gas Input Gas Output I2 Rated WeldingCurrent

    X Duty Cycle Direct Current Line Connection U2 Conventional LoadVoltage

    U1 Primary Voltage IP Degree OfProtection I1maxRated MaximumSupply Current I1eff

    Maximum EffectiveSupply Current

    U0Rated No Load

    Voltage (Average)Pulse Background

    Amperage Initial AmperageIncrease/Decrease

    Of Quantity

    Normal TriggerOperation (GTAW)

    Two-Step TriggerOperation (GTAW)

    Four-Step TriggerOperation (GTAW) Percent

    Hz Hertz Recall FromMemory Arc Force (DIG) Impulse Starting(GTAW)

    Final Slope Final AmperagePulse Percent

    On Time Initial Slope

    Contactor Control(Stick) Pulser On-Off

    TIG Weld AmpsAnd Peak Amps

    While PulsingPulse Frequency

  • OM-2222 Page 13

    SECTION 3 INSTALLATION3-1. Specifications

    A. For Multivoltage Units

    InputPower

    Rated Output at60% Duty Cycle

    WeldingAmperage

    Range

    Max.Open-Circuit

    Voltage

    Amperes Input AtRated Output, 60Hz

    KVA KW DimensionsNet

    WeightPower 60% Duty Cycle AmperageRange

    Open-CircuitVoltage 230 460

    KVA KW Dimensions Weight

    Three-Phase

    250 A @ 30 VDC,60% Duty Cycle 5 300 95

    25.40.23*

    16.20.14*

    12.80.11*

    8.80.06* H: 17 in (432 mm)

    W: 12-1/2 in (318 mm)

    82 lb(37 kg)100 lb

    (45 kg) Single-Phase

    200 A @ 28 VDC,60% Duty Cycle 5 300 95

    40.20.32* -

    9.30.11*

    6.80.06*

    W: 12-1/2 in (318 mm)

    D: 24 in (610 mm)

    100 lb(45 kg) w/aux.power

    *While idling

    B. For Single Voltage Units

    Rated Output at60% Duty Cycle

    WeldingAmperage

    Range

    Max.Open-Circuit

    Voltage

    Amperes InputAt Rated Output,

    50Hz - Three-Phase 400 VKVA KW Dimensions

    NetWeight

    250 A @ 30 VDC,60% Duty Cycle 5 300 95

    16.90.15*

    11.70.10*

    8.60.03*

    H: 17 in (432 mm)

    W: 12-1/2 in (318 mm)

    D: 24 in (610 mm)

    82 lb(37 kg)100 lb

    (45 kg) w/aux.power

    *While idling

    3-2. Volt-Ampere Curves

    ST-190 014

    Volt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofwelding power source. Curves ofother settings fall between curvesshown.

  • OM-2222 Page 14

    3-3. Duty Cycle And Overheating

    ST-186 863 / ST-190 012

    Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.

    If unit overheats, output stops, aHelp message is displayed (seeSection 5-3), and cooling fan runs.Wait fifteen minutes for unit to cool.Reduce amperage or voltage, orduty cycle before welding.

    Exceeding duty cycle candamage unit and voidwarranty.

    250 A @ 60% Duty Cycle For Three-Phase Models

    6 Minutes Welding 4 Minutes Resting

    200 A @ 60% Duty Cycle For Single-Phase Models

    Overheating

    0

    15

    A or V

    ORReduce Duty CycleMinutes

  • OM-2222 Page 15

    3-4. Selecting A Location

    1 Lifting Handles

    Use handles to lift unit.

    2 Hand Cart

    Use cart or similar device to moveunit.

    3 Rating Label (Non CEModels)

    Use rating label to determine inputpower needs.

    4 Plate Label (CE Models)

    5 Line Disconnect Device

    Locate unit near correct inputpower supply.

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

    Movement

    2

    Do not move or operate unitwhere it could tip.

    Location And Airflow5

    3

    18 in(460 mm)

    18 in(460 mm)

    ST-802 137

    1

    1

    4

    24 in(610 mm)

    17 in(432 mm)

    12-1/2 in(318 mm)

    Dimensions And Weight82 lb (37 kg) 100 lb (45 kg) w/aux power

  • OM-2222 Page 16

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

    Ref. ST-801 866

    1 AC Duplex Receptacle

    115 V 10 A for 230/460 volt models.115 V 7 A for 400 volt models.

    2 Circuit Breaker CB1

    CB1 protects duplex receptaclefrom overload.

    Press button to reset breaker.

    3 Power On/Off Switch

    2

    1

    3

    3-6. Weld Output Terminals And Selecting Cable Sizes

    Total Cable (Copper) Length In Weld Circuit Not Exceeding

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

    250 ft(70 m)

    300 ft(90 m)

    350 ft(105 m)

    400 ft(120 m)

    Weld OutputTerminals

    WeldingAmperes

    10 60%DutyCycle

    60 100%DutyCycle

    10 100% Duty Cycle

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

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

    200 3 2 1 1/0 2/0 3/0 4/0 4/0

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

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

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

    *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampereContact your local distributor for the mm2 equivalent weld cable size.**Select weld cable size for pulsing application at peak amperage value.NOTE: For proper installation of gas hose, the use of a quick-connect torch (such as a Weldcraft QWP-17 or QWP-20) is recommended

    .. S-0007-D

  • OM-2222 Page 17

    3-7. Remote 14 Receptacle Information

    A JB K I

    Socket* Socket InformationA J

    B K I

    C L N H 24 VOLTS DCA Contactor control 24 volts dc.

    C L N H

    D M GE F

    24 VOLTS DC

    OUTPUTCONTACTOR

    B Contact closure to A completes 24 volts dccontactor control circuit and enables output.

    REMOTE

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

    REMOTEOUTPUT

    CONTROLD Remote control circuit common.

    CONTROLE 0 to +10 volts dc input command signal from

    remote control.

    A/VAMPERAGE

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

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

    ST-802 137 GND K Chassis common.

    *The remaining sockets are not used.

    3-8. Remote Program Select Inputs (Optional For Non CE Models)

    10-Pin Receptacle RC2

    Pin Designations 0 = No Connection / 1 = Connected To Ground (Pin G)

    X= Do Not Care

    Function C F E D

    No Remote Control 0 0 X X

    Stick EP Of Current Program 1 0 X X

    Program 1 Stick EP 1 1 0 0

    Program 2 Stick EP 1 1 0 1

    Program 3 Stick EP 1 1 1 0

    Program 4 Stick EP 1 1 1 1

    AJ

    BH

    GProgram 1 TIG EN 0 1 0 0J

    B

    IC

    G

    FProgram 2 TIG EN 0 1 0 1

    IC

    D E

    F

    Program 3 TIG EN 0 1 1 0

    Program 4 TIG EN 0 1 1 1

    ST-802 137

    *The remaining sockets are not used.

    Socket A Contactor control, 24 volts dc

    *The remaining sockets are not used.Socket B Contact closure to A, completes 24 volts dc

    contactor control circuit and enables output

    Socket G Chassis Ground

    Socket I Normally open valid arc relay

    Socket J Circuit common for valid arc relay

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

    gram is selected.

  • OM-2222 Page 18

    3-9. Gas Connections

    ST-801 866

    1 Gas Fitting

    Fittings have 5/8-18 right-handthreads.

    2 Cylinder Valve

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

    3 Regulator/Flowmeter

    4 Flow Adjust

    Typical flow rate is 15 cfh (cubicfeet per hour).

    Connect customer supplied gashose between regulator/flowmeterand gas fitting on rear of unit.

    Tools Needed:

    3 24

    1

    5/8, 1-1/8 in

    3-10. Electrical Service Guide

    A. For Multivoltage Units

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

    NOTE

    Input VoltageThree-Phase Single-Phase

    Input Voltage230 460 230

    Input Amperes At Rated Output 25 15.8 40.2

    Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 50 25 60

    Min Input Conductor Size In AWG/Kcmil 10 14 8

    Max Recommended Input Conductor Length In Feet (Meters) 123 (38) 197 (60) 139 (42)

    Min Grounding Conductor Size In AWG/Kcmil 10 14 10

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

    B. For Single Voltage Units

    Input Voltage 400

    Input Amperes At Rated Output 16.9

    Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 25

    Min Input Conductor Size In AWG/Kcmil 14

    Max Recommended Input Conductor Length In Feet (Meters) 153 (47)

    Min Grounding Conductor Size In AWG/Kcmil 14

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

  • OM-2222 Page 19

    Check input voltage available atsite.

    1 Input And GroundingConductors

    2 Line Disconnect Device

    See Section 3-10.

    For non-CE three-phaseoperation: Always connect green wire

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

    Connect black, white, and redwires (L1, L2, L3) to line terminals.

    For CE three-phaseoperation: Always connect green/yel-

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

    Connect black, brown, and bluewires (L1, L2, L3) to line terminals.

    For single-phase operation:

    Always connect green wireto supply grounding termi-nal, never to a line terminal.

    3 Black And White InputConductor

    4 Red Input Conductor

    5 Insulation Sleeving

    6 Electrical Tape

    Insulate and isolate red conductoras shown.

    L1

    22

    1

    1

    1

    3

    1

    65

    4

    L2

    L3

    L1

    L2

    Always connect groundingconductor first.

    13

    = GND/PE

    Green OrGreen/Yellow

    Green

    Green

    input_2 3/96 - ST-802 138

    3-11. Connecting Input Power

  • OM-2222 Page 20

    SECTION 4 OPERATION

    4-1. Controls

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

    ST-188 476-B / Ref. ST-801 866

    6

    4

    7

    1

    23

    9

    10

    11

    12

    23

    25

    215

    24

    22

    8

    20

    26

    Rear Panel

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

    MemoryFunction

    Keys

  • OM-2222 Page 21

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

    ST-186 715-A / Ref. ST-801 866

    6

    4

    7

    1

    23

    9

    10

    11

    12

    23

    25

    21

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

    5

    24

    22

    8

    20

    26

    Rear Panel

    MemoryFunction

    Keys

  • OM-2222 Page 22

    4-2. Description Of Controls (Use With Sections A And B)

    For all front panel switch pad controls:press switch pad to turn on light andenable function.

    1 Encoder Control

    Use encoder control in conjunction withapplicable front panel function switch padsto change values for that function.

    2 Ammeter

    Displays amperage and preset parame-ters for pulse frequency, % of backgroundamperage, % of dig, and % of peak time.

    3 Voltmeter

    Displays arc voltage and the following pre-set times (preflow, initial slope, final slope,and postflow) in seconds, for applicablefunction controls.

    4 4 T (Specific Trigger Method)

    See Section 4-5.

    To reconfigure 4T control for use as Spot,Contactor On Lift-Arc , and Mini Logiccontrol, see Section 4-6.

    5 Remote Trigger (2T) Hold Mode

    See Section 4-4.

    6 Remote Trigger (Normal) Mode

    See Section 4-3.

    7 Lift-Arc Start ModeSee Section 4-10.

    8 HF Start Mode

    See Section 4-10.

    9 Preflow Time Control

    Press switch pad and turn Encoder Controlto set time, 015 seconds, gas flows be-fore welding electrode is energized. Pre-flow control is disabled if Lift-Arc Startmode is selected.

    Application:

    Preflow is used to purge the immediateweld area of atmosphere. Preflow alsoaids in consistent arc starting.

    10 Initial Amperage Control

    Press switch pad and turn encoder controlto select a starting amperage, 5300amps, that is different from the weld am-perage.

    Application:

    Initial Amperage can be used while GTAWwelding to assist in preheating a cold ma-terial prior to depositing filler material.

    11 Initial Slope Time Control

    Press switch pad and turn Encoder Control

    to select length of time, 025 seconds, thatit takes to slope the amperage up/downfrom start amperage to weld amperage.

    12 TIG Weld Amps And Peak AmpsWhile Pulsing Control

    Press switch pad and turn Encoder Controlto select 5300 amps for TIG welding, orpeak amps while pulsing.

    13 Final Slope Time Control

    Press switch pad and turn Encoder Controlto select length of time, 025 seconds, thatit takes to slope the amperage up/downfrom weld amperage to final amperage.

    Application:

    Final Slope Time should be used whileGTAW welding materials that are cracksensitive, and/or the operator wants toeliminate the crater at the end of the weld.

    Note: This applies if the operator is usingan on/off only type control to start and stopthe welding process.

    14 Final Amperage Control

    Press switch pad and turn Encoder Controlto select 5300 amps of final amperage.Final amperage is the amperage to whichthe weld amperage has sloped up/downto.

    15 Postflow Time Control

    Press switch pad and turn Encoder Controlto set time, 050 seconds, gas flows afterwelding stops.

    Application:

    Postflow is required to cool tungsten andweld, and to prevent contamination oftungsten and weld. Increase postflow timeif tungsten or welds are dark inappearance.

    16 Pulser On/Off Control

    Press switch pad to turn on light and en-able pulser function.

    Application:

    Pulsing refers to the alternating raising andlowering of the weld output at a specificrate. The raised portions of the weld outputare controlled in width, height, and fre-quency, forming pulses of weld output.These pulses and the lower amperage lev-el between them (called the backgroundamperage) alternately heat and cool themolten weld puddle. The combined effectgives the operator better control of pene-tration, bead width, crowning, undercut-

    ting, and heat input. Controls can be ad-justed while welding.

    Pulsing can also be used for filler materialaddition technique training.

    17 Pulse Frequency Control

    Press switch pad and turn Encoder Controlto set pulse frequency, .1500 pps (pulsesper second).

    18 Pulse Width Control

    Press switch pad and turn Encoder Controlto set percentage of time, 595%, amper-age is at peak for each pulse.

    19 Background Amperage Control

    Press switch pad and turn Encoder Controlto set background amperage as a percen-tage, 595%, of peak amperage.

    20 TIG Process Select Mode

    Press switch pad to select TIG Process.

    21 14 Program Storage

    Each program switch pad, 14, is capableof storing two welding parameters pro-grams, four for TIG, or four for Stick, de-pending on whether TIG function or Stickfunction switches are enabled. A total ofeight welding parameter programs can berecalled. The weld parameters and se-lected memory positions are updated any-time a parameter is changed. To recall aprogram, press the desired process switchpad, and program pad 14.

    22 Stick Process Select Mode

    Press switch pad to select Stick process.

    23 Output Contactor Control (Stick)

    Press switch pad to turn on light and en-able output.

    24 Stick Amperage Control

    Press switch pad and adjust Encoder Con-trol to select 5300 amps for Stick welding.

    25 DIG Control

    Press switch pad and adjust Encoder Con-trol to set DIG (0100%).

    When set lower, short-circuit amperage atlow arc voltage is the same as normalwelding amperage.

    When set higher, short-circuit amperage isincreased at low arc voltage to help witharc starting and making overhead or verti-cal welds, as well as to reduce stickingwhile welding.

    26 Power On/Off Switch

    Located on rear panel.

  • OM-2222 Page 23

    4-3. Remote Trigger (Normal) Mode

    1 Remote Switch Pad

    Press switch pad to activate func-tion.

    Torch trigger operation is as shown.

    NOTE: When a foot or finger remotecontrol is connected to the weldingpower source, initial amps, initialslope, final slope, and final ampsare not functional.

    NOTE: Initial weld amperage and fi-nal amperage is controlled by theremote device, not by the weldingpower source.

    NOTE: If On/Off only type trigger isused, it must be a maintainedswitch. All functions become active.

    Application: Use Remote Triggerwhen the operator desires to use afoot pedal or finger amperage con-trol.

    1

    Current (A)

    Preflow

    Initial Amps

    Initial Slope Final Slope

    Postflow

    Weld Amps

    Final Amps

    Release ForMaintained Switch

    Torch Trigger Operation

    Release Foot OrFinger RemoteControl

    Push & HoldFoot Or FingerRemote Control

  • OM-2222 Page 24

    4-4. Remote Trigger (2T) Hold Mode

    1 Remote Trigger Hold SwitchPad

    Press switch pad to activate func-tion.

    Torch trigger operation is as shown.

    NOTE: When a foot or finger remotecontrol is connected to the weldingpower source, only trigger input isfunctional.

    NOTE: Amperage is controlled bythe welding power source.

    Application: Use Remote TriggerHold (2T) when long extendedwelds are made. Remote TriggerHold (2T) can help to reduce opera-tor fatigue.

    1

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

    Current (A)

    Preflow

    Initial Amps

    Initial Slope Final Slope

    Postflow

    Push & Release TriggerIn Less Than 3/4 Sec.

    Weld Amps

    Final Amps

    Torch Trigger Operation

    Push & Release TriggerIn Less Than 3/4 Sec.

  • OM-2222 Page 25

    4-5. 4T (Specific Trigger Method)

    1 4T Switch Pad

    Press switch pad to activate func-tion.

    Torch trigger operation is as shown.

    While in 4T mode, there is a featureavailable during the main weld se-quence that allows the operator totoggle between weld current andfinal current without breaking thearc.

    NOTE: When a remote switch isconnected to the welding powersource, only trigger input is func-tional. Amperage is controlled bythe welding power source.

    Application:

    Use 4T trigger method when thefunctions of a remote current controlare desired, but only a remote on/offcontrol is available.

    1

    Current (A)

    Preflow

    Initial Amps

    Initial Slope Final Slope

    Postflow

    Push & HoldTrigger

    ReleaseTrigger

    Push & HoldTrigger

    ReleaseTrigger

    Push & ReleaseTrigger In LessThan 3/4 Sec.

    Weld Amps

    Final Amps

    Torch Trigger Operation

    Push & ReleaseTrigger In LessThan 3/4 Sec.

  • OM-2222 Page 26

    4-6. Reconfiguring 4T For Mini Logic Control, Spot, Contactor On, Or Lift-Arc

    1 4T Switch Pad

    2 Power Switch

    To reconfigure 4T, push and hold 4Tswitch pad and turn On powerswitch. Hold switch pad for approxi-mately 7 seconds (or until softwareversion number _ _ _ _ _ _-_clears,and meters display [-] [H4]).

    3 Encoder Control

    Use Encoder to change functions.Active function will be displayed onamperage (right) meter.

    4 Meter Displays

    Meter displays for the different func-tions will be as shown.

    Press torch trigger or turn power Offto save setting. Lift-Arc requires apower down.

    Proceed to Section 4-7 for MiniLogic operation.

    Proceed to Section 4-8 for SpotControl Operation.

    Proceed to Section 4-9 for Contac-tor On Lift-Arc Operation.

    1

    Rear Panel

    2

    3

    H4

    H4

    H4L

    SPO

    O1

    =

    =

    =

    =

    4T (See Section 4-5)

    Mini Logic (See Section 4-7)

    Spot (See Section 4-8)

    Lift-Arc (See Section 4-9)

    4

  • OM-2222 Page 27

    4-7. Mini Logic Operation

    1 Mini Logic Meter Display

    Select Mini Logic according to Sec-tion 4-6.

    Torch trigger operation is asshown.

    During Mini Logic welding opera-tion, the weld current can be manu-ally changed from the initial ampslevel to the main weld amps levelby pressing and releasing the torchtrigger in less than 3/4 seconds.

    NOTE: When a remote switch isconnected to the welding powersource, only trigger input is func-tional. Amperage is controlled bythe welding power source.

    Application: This ability to changecurrent levels without either initialslope or final slope, gives the oper-ator the opportunity to adjust fillermetal without breaking the arc.

    H4L = Mini Logic

    1

    Preflow

    Start Amps

    Initial Slope Final Slope

    Postflow

    Weld Amps

    Push & HoldTrigger For MoreThan 3/4 Sec.

    Torch Trigger Operation

    Release Trigger

    Final SlopeRate

    Push & ReleaseTrigger In LessThan 3/4 Sec.

    Final SlopeRate

    Initial Amps

    Push & ReleaseTrigger In LessThan 3/4 Sec.

    Push & HoldTrigger For MoreThan 3/4 Sec.

    Push & ReleaseTrigger In LessThan 3/4 Sec.

    Push & ReleaseTrigger In LessThan 3/4 Sec.

    Push & HoldTrigger For MoreThan 3/4 Sec.

    Push & HoldTrigger

  • OM-2222 Page 28

    4-8. Spot Control Operation

    1 Spot Function Meter Display

    Select Spot function according toSection 4-6.

    2 TIG Weld Amps And PeakAmps While Pulsing SwitchPad

    3 Encoder Control

    Set spot parameters as follows:Press switch pad once (amps LEDlights) and turn Encoder to set spotamperage. Press switch pad again(seconds LED lights) and turn En-coder to set spot time (.125 sec-onds).

    NOTE: When a remote switch isconnected to the welding powersource, only trigger input is func-tional. Amperage is controlled bythe welding power source.

    Torch trigger operation is asshown.

    Application: To provide a timedweld. Used for tacking, and thinsheet joining.

    SPO = Spot

    1

    3

    2

    Current (A)

    Preflow Postflow

    Timed Spot Weld Amps

    Push & HoldTrigger

    Torch Trigger Operation

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

    ReleaseTrigger

  • OM-2222 Page 29

    4-9. Contactor On Lift-Arc Operation

    1 Contactor On Lift-Arc MeterDisplay

    Select Contactor On Lift-Arc func-tion according to Section 4-6.

    Proceed to Section 4-10 Lift-Arcstart procedures.

    Application: Lift-Arc is used forthe DCEN GTAW process whenthe HF start method is not per-mitted, or to replace the scratchstart method. Also, allows for theuse of Lift-Arc without a remote on/off switch.

    O1= Lift-Arc

    1

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

    4-10. Lift-Arc And HF TIG Start Procedures

    Lift-Arc Start

    When Lift-Arc button light is On,start arc as follows:

    1 TIG Electrode

    2 Workpiece

    Touch tungsten electrode to work-piece at weld start point, enableoutput with torch trigger, foot con-trol, or hand control. Holdelectrode to workpiece for 1-2seconds, and slowly lift electrode.An arc will form when electrode islifted.

    Normal open-circuit voltage is notpresent before tungsten electrodetouches workpiece; only a lowsensing voltage is present be-tween electrode and workpiece.The solid-state output contactordoes not energize until after elec-trode is touching workpiece. Thisallows electrode to touch work-piece without overheating,sticking, or getting contaminated.

    Application:

    Lift-Arc is used for the DCENGTAW process when HF Startmethod is not permitted, or to re-place the scratch method.

    HF Start

    When HF Start button light is On,start arc as follows:

    High frequency turns on to helpstart arc when output is enabled.High frequency turns off when arcis started, and turns on wheneverarc is broken to help restart arc.

    1

    1 2SecondsTouch

    Do NOT Strike Like A Match!

    2

  • OM-2222 Page 30

    4-11. Programmable HF Start Amperage And Time Modes

    A. Accessing Programmable HF Start Amperage And Time Modes

    NOTE: Before accessing program-mable HF start amperage and timemodes, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile programmable HF start andtime modes are active.

    1 Lift-Arc And HF Start ModeSwitch Pads

    2 Power Switch

    To display the programmable HFstart amperage and time screens,push and hold Lift-Arc and HF Startswitch pads and turn On powerswitch. Hold switch pads forapproximately 7 seconds (or untilsoftware version number _ _ _ _ __-_clears meters).

    Proceed to Section B and/or C.

    1

    Rear Panel

    2

    B. Setting Programmable HF Start Amperage

    NOTE: Before accessing programmableHF start amperage mode, be sure that allprocedures and parameters are estab-lished. Parameter adjustment is limitedwhile programmable HF start amperagemode is active.Welding cycle can be executed while inprogrammable start mode, but programparameters cannot be adjusted while inthis mode.1 Initial Amps Switch Pad

    2 Memory Program Switch Pads (14)3 Encoder Control

    To adjust HF start amperage proceed asfollows:

    Press desired memory switch pad (14) toactivate desired memory program andturn on LED.

    Press Initial Amps switch pad. Switch padLED turns on, meter A LED turns on, and[5 ] [50 ] is displayed on meters.

    The 50 displayed on the amps meter isDC start amps (it is also the factory defaultsetting), and can be adjusted from 1 to 200amps by turning the Encoder control.

    To change start time, proceed to SectionC. To save changes to HF start amperagewithout changing start time, select a differ-ent memory program number, or turn pow-er Off.

    2

    1

    3

    5 50

  • OM-2222 Page 31

    C. Setting Programmable Start Time

    2

    1

    NOTE: Before accessing programmablestart time mode, be sure that all proce-dures and parameters are established.Parameter adjustment is limited while pro-grammable start time mode is active.

    Welding cycle can be executed while inprogrammable start mode, but programparameters cannot be adjusted while inthis mode.

    1 Initial Slope Switch Pad

    2 Memory Program Switch Pads (14)

    3 Encoder Control

    To adjust start time proceed as follows:

    If you are adjusting start time without hav-ing adjusted start amperage in Section B,press desired memory switch pads (14)to activate desired memory program andturn on LED.

    Press Initial Slope switch pad. Switch padLED turns on, meter S LED turns on, and[5 ] [1 ] is displayed on meters.The [1 ] displayed on the amps meter is DCstart time (it is also the factory default set-ting), and can be adjusted from 1 to 200milliseconds by turning the Encodercontrol.To save changes, select a differentmemory program number, or turn powerOff.

    3

    5 1

  • OM-2222 Page 32

    4-12. Arc Timer/Counter Display

    1 Initial And Final Slope ControlSwitch Pads

    2 Power Switch

    To display the arc timer/counter,push and hold Initial and FinalSlope control switch pads, and turnOn Power switch. Hold switchpads for approximately 7 seconds(or until software version number _ _ _ _ _ _-_clears meters).

    3 Arc Timer Display

    Upon power up as describedabove, the meter S and Memory 1LEDs will turn on, and arc time willbe displayed for 5 seconds as [000000 ] to [999 999 ]. The first fournumbers indicate hours, and thelast two numbers indicate minutes.Arc time shown in example is readas 1,234 hours and 56 minutes.Maximum arc time is 9,999 hoursand 59 minutes.

    4 Arc Counter

    After 5 seconds, the meter A andMemory 2 LEDs turn on, and thearc counter will be displayed for thenext 5 seconds as [000 000 ] to [999999 ]. The maximum arc cyclecount is 999 999.

    1 1

    Arc Timer3

    Arc Counter

    1 2 3 4 5 6

    49 9 9

    Rear Panel

    2

    9 9 9

  • OM-2222 Page 33

    4-13. Lock Out Functions

    A. Accessing Lock Out Capability

    See Section 4-1 for explanation of controls referred to in all ofSection 4-13.

    There are four (14) different lock out levels. Each successive levelallows the operator more flexibility.

    NOTE: Before activating lock out levels, be sure that all proceduresand parameters are established. Parameter adjustment is limitedwhile lock out levels are active.

    1 Memory Program Buttons 3 And 42 Power Switch

    To access lock-out screens, press and hold memory programswitch pads 3 and 4, and turn On power switch. Hold switch padsfor approximately 7 seconds (or until software version number _ __ _ _ _-_clears meters).

    3 Lock Out Off

    If meter display is as shown, lockout feature is off.

    4 Lock-Out On

    If meter display is as shown, lockout feature is on.

    To turn On the lock out feature, proceed as follows:

    Enter a three digit code using the four Memory Program switchpads. NOTE: If any switch pad other than a numbered Memory Pro-

    gram switch pad is used, the lock out code is cancelled, and the lockout condition will remain inactive.Once three digits have been entered, the amperage screen displaywill change from [L0 ] to [L ].There are four lock out levels available. Enter any single digit (14),using the Memory Program switch pads, to access a lock out level(see Sections B and/or C).Press torch trigger or turn Off power to complete lock out Onsequence.To turn Off the lock out feature, proceed as follows:To access lock-out screens, press and hold memory programswitch pads 3 and 4, and turn On power switch. Hold switch padsfor approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears meters).Enter the same three digits that were used to turn on the lock outfeature. NOTE: If any switch pad other than a numbered MemoryProgram key pad is used, the code is cancelled, and the lock outcondition will remain On.Once the correct three digits have been entered, the amperagescreen display will change from [L-1 ] or 2,3,4 to [L0 ].Press torch trigger or turn Off power to complete lock out Offsequence.

    Rear Panel

    2

    1

    L0L 0

    L0L1

    3

    4

    or 2,3,4

  • OM-2222 Page 34

    B. Lock Out Levels

    Level 1

    NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile lock out levels are active.

    NOTE: Remote amperage controlis not available in level 1.

    Trigger Selection

    Allows for normal, 2T, or 4T triggermode to be selected if the TIG pro-cess was selected when lock outfeature was activated.

    Stick Contactor Control

    Allows for contactor control if theStick process was selected whenlock out feature was activated.

    Level 2

    NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile lock out levels are active.

    NOTE: Remote amperage controlis not available in level 2.

    Includes all the functions of level 1plus the following:

    Program Selection 14

    Gives operator the ability to selectdesired program.

    Process Selection TIG or Stick

    Gives operator the ability to selectthe TIG or Stick process.

    Lift-Arc Or HF Start Mode

    Gives operator the ability to selectLift-Arc or HF Start mode.

    Select TIG

    Contactor Control (Stick)

    Process Selection

    Program Selection

    Lift-Arc Or HF Start Mode Selection

    Level 1

    Level 2

    or Stick

    Select desired program

    Select Lift-Arc OrHF Start mode

    Trigger Selection (TIG)Or

    Or

  • OM-2222 Page 35

    C. Lock Out Levels (Continued)

    Level 3

    +/ 10 % Amperage Adjust Control

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

    Level 4

    Remote Amperage Control

    Level 3

    NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile lock out levels are active.

    NOTE: Remote amperage control isnot available in level 3.

    Includes all the functions of levels 1and 2 plus the following:

    +/ 10% adjustment of preset TIGWeld Amps or Peak Amps WhilePulsing or Stick Weld Amps

    Select desired amperage control(TIG or Stick, and use Encoder con-trol to adjust amperage +/ 10% ofpreset amperage value, up to thelimits of the machine.

    Pulser ON/Off Control

    Gives operator the ability to turn on/off the Pulser control.

    Level 4

    NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adjustment is limitedwhile lock out levels are active.

    Includes all the functions of levels 1,2, and 3 plus the following:

    Remote Amperage Control

    Allows operator to use remote am-perage control if desired. Remotecontrol operates from minimum tomaximum of preset amperage val-ue. Connect remote control deviceaccording to Section 3-7.

    A JB

    K I

    C L N H

    D M GE F

    Pulser On/Off Control

    Turn Pulser control on/off

  • OM-2222 Page 36

    SECTION 5 MAINTENANCE AND TROUBLESHOOTING

    5-1. Routine Maintenance

    Disconnect power before maintaining.

    Maintain more often during severe conditions.

    3 Months

    Replaceunreadablelabels.

    Clean and tightenweld terminals.

    Replace DamagedGas Hose

    3 Months

    Repair Or ReplaceCracked CablesAnd Cords

    6 Months

    Blow out inside. Duringheavy service cleanmonthly.

    Do not remove case when blowing out inside of unit(see Section 5-2) .

    5-2. Blowing Out Inside Of Unit

    Do not remove case whenblowing out inside of unit.

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

    ST-802 137

  • OM-2222 Page 37

    5-3. Voltmeter/Ammeter Help Displays

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

    0 Help 0 Display

    Indicates a short in the thermal protectioncircuitry located on the left side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.

    1 Help 1 Display

    Indicates a malfunction in the primary pow-er circuit. Contact a Factory AuthorizedService Agent if this display is shown.

    2 Help 2 Display

    Indicates an open in the thermal protectioncircuitry located on the left side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.

    3 Help 3 Display

    Indicates the left side of the unit has over-heated. The unit has shut down to allow the

    fan to cool it (see Section 3-3). Operationwill continue when the unit has cooled.

    4 Help 4 Display

    Indicates an open in the thermal protectioncircuitry located on the right side of the unit.Contact a Factory Authorized ServiceAgent if this display is shown.

    5 Help 5 Display

    Indicates the right side of the unit has over-heated. The unit has shut down to allow thefan to cool it (see Section 3-3). Operationwill continue when the unit has cooled.

    6 Help 6 Display

    Indicates that the input voltage is too lowand the unit has automatically shut down.Operation will continue when the voltage iswithin the operating range (10%). Havean electrician check the input voltage if thisdisplay is shown.

    7 Help 7 Display

    Indicates that the input voltage is too highand the unit has automatically shut down.Operation will continue when the voltage iswithin the operating range (10%). Havean electrician check the input voltage if thisdisplay is shown.

    8 Help 8 Display

    Indicates a malfunction in the secondarypower circuit of the unit. Contact a FactoryAuthorized Service Agent if this display isshown.

    9 Help 9 Display

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

    10 Help 10 Display

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

    1AV

    2AV

    3AV

    HE.L P1

    HE.L P2

    HE.L P3

    4AV

    HE.L P4

    5AV

    HE.L P5

    6AV

    HE.L P6

    7AV

    HE.L P7

    8AV

    HE.L P8

    0V

    HE.L P0

    9AV

    HE.L P9

    10AV

    HE.L P10

    A

  • OM-2222 Page 38

    5-4. Troubleshooting

    Trouble Remedy

    No weld output; unit completelyinoperative.

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

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

    Check for proper input power connections (see Section 3-11).

    No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14receptacle (see Section 3-7 as applicable).

    Input voltage outside acceptable range of variation (see Section 3-10).

    Check, repair, or replace remote control.

    Unit overheated. Allow unit to cool with fan On (see Section 3-3).

    Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-6).

    Clean and tighten all weld connections (see Section 3-6).

    No 115 volts ac output at duplexreceptacle.

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

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

    Have Factory Authorized Service Agent check fan motor.

    Wandering arc Use proper size tungsten (see Section 8).

    Use properly prepared tungsten (see Section 8).

    Reduce gas flow rate (see Section 3-9).

    Tungsten electrode oxidizing and notremaining bright after conclusion of

    Shield weld zone from drafts.remaining bright after conclusion ofweld. Increase postflow time (see Section 4-1).

    Check and tighten all gas fittings (see Section 3-9).

    Water in torch. Refer to torch manual.

  • OM-2222 Page 39

    Notes

  • OM-2222 Page 40

    SECTION 6 ELECTRICAL DIAGRAMS

    Figure 6-1. Circuit Diagram For 230/460 Volt Models

  • OM-2222 Page 41

    SC