MIller Dynasty 200 DX User Manual

5/27/2018 MIller Dynasty 200 DX User Manual

1/92

Visit our website at

www.MillerWelds.com

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

OM-2240 20768March 2005

115/230/400/460 Volt Models W/AutoArc Welding Power Source

Dynasty 200 SD And DX

And Non-CE Model


2/92

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

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

line catalog or individual catalog sheets. To locate your nearest

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

www.MillerWelds.com on the web.

Thank youand congratulationson choosing Miller. Now you can get

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

it any other way.

Thats why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldnt afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. Theyre just as committed to providing equipment and service

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

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

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

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

Weve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as youevery power source fMiller is backed by the mhassle-free warranty inbusiness.

From Miller to You

Mil_Thank 7/03


3/92

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Autres symboles relatifs l installation, au fonctionnement et l entretien de lappareil. 7. . . . . . . . . . .

2-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS (CE Models) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturers Rating Label 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3. Symbols And Definitions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. DC Volt-Ampere Curves 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. AC Volt-Ampere Curves 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Duty Cycle And Overheating 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Selecting A Location 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Weld Output Terminals And Selecting Cable Sizes* 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Remote 14 Receptacle Information 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Gas Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. TIG HF Impulse/ Lift-Arct Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Stick Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Electrical Service Guide 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Connecting Three-Phase Input Power 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Connecting Single-Phase Input Power 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 5 OPERATION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Encoder Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Amperage Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Ammeter And Parameter Display 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Voltmeter 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Polarity Control (Dynastyt Models Only) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Process Control 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8. Output Control 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Pulser Control (DX And LX Models) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10. Sequencer Controls (DX, LX And All CE Models) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12. AC Waveshape (Dynasty Models Only) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) 30. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available) 31. . . . . . . . . . . . . . . . . . . . .5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On

The Front Panel 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16. Factory Parameter Defaults And Range And Resolution 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17. Resetting Unit To Factory Default Settings 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTS

SECTION 6 ADVANCED FUNCTIONS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Programable TIG Start Parameters 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Output Control And Trigger Functions 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Arc Timer/Counter Display 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Lockout Functions 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) 52. . . . . . . . . . . . . . . . . . . .6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 MAINTENANCE AND TROUBLESHOOTING 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Blowing Out Inside Of Unit 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Voltmeter/Ammeter Help Displays 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Troubleshooting 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 ELECTRICAL DIAGRAMS 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 HIGH FREQUENCY (HF) 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Welding Processes Requiring High Frequency 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Correct Installation 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 SELECTING AND PREPARING TUNGSTEN ELECTRODE 59. . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Selecting Tungsten Electrode 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2. Safety Information About Tungsten 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding 60. . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 GUIDELINES FOR TIG WELDING (GTAW) 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1. Typical GTAW Set-Ups 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2. Positioning The Torch 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3. Lift-ArcE And HF TIG Start Procedures 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4. Torch Movement During Welding 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5. Positioning Torch Tungsten For Various Weld Joints 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 STICK WELDING (SMAW) GUIDELINES 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 67. . . . . . . . . . . . . . . . . . . . . . .12-2. Electrode and Amperage Selection Chart 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-3. Stick Welding Procedure 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4. Striking an Arc Scratch Start Technique 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5. Striking an Arc Tapping Technique 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6. Positioning Electrode Holder 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7. Poor Weld Bead Characteristics 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8. Good Weld Bead Characteristics 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-9. Conditions That Affect Weld Bead Shape 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-10. Electrode Movement During Welding 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11. Butt Joints 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12. Lap Joint 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13. Tee Joint 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14. Weld Test 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15. Troubleshooting Porosity 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-16. Troubleshooting Excessive Spatter 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-17. Troubleshooting Incomplete Fusion 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-18. Troubleshooting Lack Of Penetration 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-19. Troubleshooting Excessive Penetration 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-20. Troubleshooting Burn-Through 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21. Troubleshooting Waviness Of Bead 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-22. Troubleshooting Distortion 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 PARTS LIST 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND ACCESSORIESWARRANTY


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dec_con1_11/02

Declaration of Conformity ForEuropean Community (CE) Products

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

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

Appleton, WI 54914 USA

Declares that the product: Dynasty 200 SD And 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. Danilo Fedolfi, Managing DirectorITW WELDING PRODUCTS ITALY S.r.l.Via Privata Iseo 6/E20098 San GiulianoMilanese, Italy

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


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Notes


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OM-2240 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/03

1-1. Symbol Usage

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

Marks a special safety message.

Means Note; not safety related.

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

1-2. Arc Welding Hazards

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

Only qualified persons should install, operate, maintain, and

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

ELECTRIC SHOCK can kill.

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

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

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the workor ground.

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

Use AC output ONLY if required for the welding process.

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

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

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

Always verify the supply ground check and be sure that input

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

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

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

Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

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

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

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

Wear a safety harness if working above floor level.

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

or worktable as near the weld as practical.

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

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

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

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

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

FUMES AND GASES can be hazardous.

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

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

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

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

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

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

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

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


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

ARC RAYS can burn eyes and skin.

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

Wear approved safety glasses with side shields under yourhelmet.

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

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

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

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

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

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

Watch for fire, and keep a fire extinguisher nearby.

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

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

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

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

contact tip when not in use.

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

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

FLYING METAL can injure eyes.

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

Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch.

MAGNETIC FIELDScan affect pacemakers.

Pacemaker wearers keep away. Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

Wear approved ear protection if noise level ishigh.

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

CYLINDERS can explode if damaged.

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

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

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder explosion will result.

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

Turn face away from valve outlet when opening cylinder valve.

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

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


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

FIRE OR EXPLOSION hazard.

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

Do not install unit near flammables. Do not overload building wiring be sure power supply system is

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

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handlingboards or parts.

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

MOVING PARTS can cause injury.

Keep away from moving parts. Keep away from pinch points such as 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 electrician prompt-ly correct any interference problem resulting from the installa-tion.

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

Have the installation regularly checked and maintained.

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

ARC WELDING can cause interference.

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

Be sure all equipment in the welding area is

electromagnetically compatible. To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

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

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

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

1-4. California Proposition 65 Warnings

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

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

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

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

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

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


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1-5. Principal Safety Standards

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

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

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

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

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

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

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

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

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

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

1-6. EMF Information

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

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

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

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

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

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

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

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


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SECTION 2 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

som_fre 8/03

2-1. Signification des symboles

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

Identifie un message de scurit particulier.

Signifie NOTA ; nest pas relatif la scurit.

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

2-2. Dangers relatifs au soudage larc

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

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

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

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

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

Ne jamais toucher aux pices lectriques sous tension.

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

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

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

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

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

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

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

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

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

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

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

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

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

terre ou une lectrode dune autre machine.

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

Porter un harnais de scurit quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

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

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

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

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

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

LES FUMES ET LES GAZ peuventtre dangereux.

Se tenir distance des fumes et ne pas les inhaler.

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

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

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

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

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

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


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

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

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

Porter des lunettes de scurit crans latraux sous le masque.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

LES PARTICULES PROJETES peu-vent blesser les yeux.

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

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

masque de soudage.

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

Couper lalimentation en gaz protecteur en cas denon utilisation.

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

LES PICES CHAUDES peuvent cau-

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

dutiliser le pistolet ou la torche.

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

Les personnes qui portent un stimulateur cardiaquedoivent se tenir distance.

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

LE BRUIT peut affecter loue.

Le bruit de certains processus et quipements peutaffecter loue.

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

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

manipuler avec prcaution.

Les BOUTEILLES endommagespeuvent exploser.

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

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

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

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

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

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

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

Dtourner la tte lorsquon ouvre la soupape dune bouteille. Laisser le capuchon protecteur sur la soupape, sauf en cas dutilisa-

tion ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz compri-

m, les quipements associs et les publications P1 de la CGA,mentionnes dans les normes de scurit.


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

Risque DINCENDIE OU DEXPLO-SION

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

Ne pas installer lappareil proximit de produits inflammables.

Ne pas surcharger linstallation lectrique

sassurer que lalimen-tation est correctement dimensionne et protge avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

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

Utiliser un engin de capacit adquate pour leverlappareil.

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

LEMPLOI EXCESSIF peut FAIRESURCHAUFFER LQUIPEMENT.

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

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

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

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

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

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

LES PICES MOBILES peuvent cau-ser des blessures.

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

que les dvidoirs.

LES FILS DE SOUDAGE peuvent cau-ser des blessures.

Ne pas appuyer sur la gchette avant den avoirreu linstruction.

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

LES ORGANES MOBILES peuventcauser des blessures.

Se tenir lcart des organes mobiles comme lesventilateurs.

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

protection.

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

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

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

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

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

Faire rgulirement contrler et entretenir linstallation. Maintenir soigneusement ferms les panneaux et les portes des sour-

ces de haute frquence, maintenir le jeu dclatement au rglageadquat et utiliser une terre et un blindage pour rduire les interfren-ces ventuelles.

LE SOUDAGE LARC peut causerdes interfrences.

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

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

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

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

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

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

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

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez dis-tance.

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


14/92

OM-2240 Page 8

2-4. Principales normes de scurit

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

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

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

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

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

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

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

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

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

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

2-5. Information sur les champs lectromagntiques

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

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

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

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

2. Mettre tous les cbles du ct oppos loprateur.

3. Ne pas senrouler les cbles autour du corps.

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

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

Consignes relatives aux stimulateurs cardiaques :

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


15/92

OM-2240 Page 9

SECTION 3 DEFINITIONS (CE Models)

3-1. Warning Label Definitions

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

1 Electric shock from welding electrodeor wiring can kill.

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

1.2 Protect yourself from electric shock byinsulating yourself from work andground.

1.3 Disconnect input plug or power beforeworking on machine.

2 Breathing welding fumes can behazardous to your health.

2.1 Keep your head out of the fumes.2.2 Use forced ventilation or local exhaust

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

or fire.3.1 Keep flammables away from welding.

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

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

3.3 Do not weld on drums or any closedcontainers.

4 Arc rays can burn eyes and injureskin.

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

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

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

1 1.1 1.2 1.3

2 2.1 2.2 2.3

3 3.1 3.2 3.3

4 4.1

5

6

S-179 310-A


16/92

OM-2240 Page 10

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

1 Electric shock from wiring cankill.

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

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

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

8 Always wear long sleeves andbutton your collar whenservicing unit.

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

S-185 836

> 60 s

VV

V

1 2 3 4 5

6 7 8 9

S-179 309-A

=


17/92

OM-2240 Page 11

3-2. Manufacturers Rating Label

See Section 4-5 forlocation.

Use rating label to de-termine input powerrequirements.

S

S

20% 60% 100%

120150200

14.81618

X

2U

I 2

EN 609741

1A 10V

50/60 Hz

50/60 Hz

100%

110

24.425.2

130

60%20%

200

28

U 80Vo

1A 20V

80VoU

32 25

1635

effmaxI I1 1

IP23

1

1

f1

f2

10213 50/60 Hz

6123 50/60 Hz

5103 50/60 Hz

U 1 =115V

U 1 =230V

U 1 =230V

U 1 =400V

U 1 =460V

200A 28V

200A 18V

X

I 2

2U

100%

100

14

100%

90

23.6

40%

140

15.6

24

100

60%

U 1 =115V

U 1 =115V

20250 Hz

60 Hz

f1

f2


18/92

OM-2240 Page 12

3-3. Symbols And Definitions

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

V Volts Voltage Input 3 Phase Static FrequencyConverter-Transformer-Rectifier

Voltage Output Circuit Breaker Remote

Lift-Arc 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 U2Conventional Load

Voltage

U1 Primary Voltage IPDegree OfProtection I1max

Rated MaximumSupply Current I1eff

Maximum EffectiveSupply Current

U0Rated No Load

Voltage (Average)Pulse Background

Amperage Initial AmperageIncrease/Decrease

Of Quantity

Normal Trigger Op-eration (GTAW)

Two-Step TriggerOperation (GTAW)

Four-Step TriggerOperation (GTAW) Percent

Hz Hertz Recall FromMemory Arc Force (DIG) HF Impulse Start-ing (GTAW)

Final Slope Final AmperagePulse Percent

On Time Initial Slope

Contactor Control(Stick) Pulser On-Off

TIG Weld AmpsAnd Peak Amps

While PulsingPulse Frequency

Background Amps Process Pulser Sequence

Output Adjust SSuitable For Areas

Of IncreasedShock Hazard


19/92

OM-2240 Page 13

SECTION 4 INSTALLATION4-1. Specifications

Welding Max.

-Amperes Input At Rated Output, 50/60Hz

nput ower ate utput AmperageRange **

pen- ircuitVoltage 115 230 400 460

Three-Phase

Stick Process130 A @ 25.2 VDC,

60% Duty Cycle 1 20080

5-10- 12.30.16*

7.60.24*

6.00.25*

4.80.06*

Three-Phase

TIG Process150 A @ 16 VDC,60% Duty Cycle 1 200

80

5-10-

9.4

0.16*

6.0

0.24*

4.7

0.25*

3.8

0.06*

Three-PhaseStick Process

200 A @ 28 VDC,20% Duty Cycle 1 200

80

5-1020.8

0.16*

13.0

0.24*

10.2

0.25*

8.1

0.06*

Three-PhaseTIG Process

200 A @ 18 VDC,20% Duty Cycle 1 200

80

5-1013.7

0.16*

8.7

0.24*

6.9

0.25*

5.5

0.06*

Single-Phase

Stick Process130 A @ 25.2 VDC,

60% Duty Cycle 1 20080

5-10 -20.00.23* -

10.0

.25*4.7

0.05*

Single-Phase


80

5-10-

15.8

0.23*-

7.9

.25*

3.6

0.05*

Single-Phase

Stick Process100 A @ 24 VDC,60% Duty Cycle 1 200

80

5-1031.30.42* - - -

3.60.05*

Single-Phase

TIG Process 140 A @ 15.6 VDC,40% Duty Cycle 1 200 805-10

31.00.42* - - -3.6

0.05*

Single-Phase

Stick Process90 A @ 23.6 VDC,100% Duty Cycle 1 200

80

5-1027.60.42* - - -

3.2

0.05*

Single-Phase


80

5-1020.70.42* - - -

2.3

0.05*

*While idling

** Welding range for AC output is 5200 amperes

Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected.Normal open-circuit voltage (80 volts) is present while in Stick with normal open-circuit voltage selected.

NOTE: Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.

NOTE: This unit is equipped with Auto-Line. The Auto-Line circuitry automatically connects to 120460 VAC, single- or three-phase power withoremoving the cover to relink the power source.


20/92

OM-2240 Page 14

4-2. DC Volt-Ampere Curves

Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of weldingpower source. Curves of other set-tings fall between curves shown.

210 168-A

3 Phase Voltage Input; DC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

V

olts

Dig Max.Stick/TIG Min.

Stick Max.

TIG Max.

230VAC Single Phase Input; DC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min. DIG Max.

115VAC Input; DC Output

0

20

40

60

80100

120

140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min.DIG Max.

*

*

*

*Amperage setting must be reduced to obtain currents less than highlighted data* point.


21/92

OM-2240 Page 15

4-3. AC Volt-Ampere Curves

Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of weldingpower source. Curves of other set-tings fall between curves shown.

210 168

115VAC Input; AC Output

0

20

40

6080

100

120

140

0 50 100 150 200 250Amperes

Vol

ts

Stick Max.

TIG Max.

Stick/TIG Min.

230VAC Single Phase Input; AC Output

0

20

40

60

80

100

120140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min.

3 Phase Voltage Input; AC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

Volts

Stick/TIG Min.

Stick Max.

TIG Max.

*

*

*

*Amperage setting must be reduced to obtain currents less than highlighted data* point.


22/92

OM-2240 Page 16

4-4. Duty Cycle And Overheating

210 167

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, output stops, aHelp message is displayed (seeSection 7-3), 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.

130 A @ 60% Duty Cycle For Stick Process (Other Voltages)

6 Minutes Welding 4 Minutes Resting

Overheating

0

15

A or V

ORReduce Duty CycleMinutes

150 A @ 60% Duty Cycle For TIG Process (Other Voltages)

90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process

100 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process

0

50

100

150

200

250

10 100

% DUTY CYCLE

OUTPUTAMPERES

STICK

TIGTIG (115V INPUT)

STICK (115V INPUT)

20 30 40 50 60 70 80 90

Continuous Welding

100%dutycycle


23/92

OM-2240 Page 17

4-5. Selecting A Location

1 Identification Plate2 Rating Label3 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.

Location And Air flow3

1

18 in (460 mm)Clearance

18 in (460 mm)Clearance

803 428-A

2

21 in(533 mm)

13-3/8 in(333 mm)

7-9/16 in(192 mm)

Dimensions And Weight

SERIAL NO.

STOCK NO.

EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY

48.5 lb (22.0 kg)

S

S

20% 60% 100%

12015020014.81618

X

2U

I2

EN 6097411A 10V

50/60 Hz50/60 Hz

100%

110

24.425.2

130

60%20%

200

28

U 80Vo

1A 20V

80VoU

32 251635

effmaxI I1 1

IP23

11

f1

f2

10213 50/60 Hz

6123 50/60 Hz

5103 50/60 Hz

U1 =115V

U1 =230VU1 =230V

U1 =400V

U1 =460V

200A 28V

200A 18V

X

I2

2U

100%

100

14

100%

90

23.6

40%

140

15.6

24

100

60%U1 =115V

U1 =115V

20250 Hz

60 Hz

f1

f2


24/92

OM-2240 Page 18

4-6. Weld Output Terminals And Selecting Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot Exceeding

Turn off power beforeconnecting to weld out-put terminals.

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)

Do not use worn, dam-aged, undersized, orpoorly spliced cables.

WeldingAmperes***

10 60%DutyCycle

60 100%DutyCycle

10 100% Duty Cycle

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

Output Receptacles

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.( ) = mm2for metric use

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

4-7. Remote 14 Receptacle Information

Socket* Socket Information

A JB K I 15 VOLTS DC

A Contactor control +15 volts dc.

C L N H

D M GF

OUTPUTCONTACTOR

B Contact closure to A completes 15 volts dccontactor control circuit and enables output.

C Output to remote control; +10 volts dc output toremote control.

REMOTEOUTPUT D Remote control circuit common.

CONTROLE 0 to +10 volts dc input command signal from

remote control.

A/V F Current feedback; +1 volt dc per 100 amperes.AMPERAGEVOLTAGE H Voltage feedback; +1 volt dc per 10 volts output.

803 428-A GND G +15 volts dc GND

CHASSIS K Chassis common.

*The remaining sockets are not used.

Note: If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on theremote control before the Panel or Remote contactor is turned on. Failure to do so, will cause current to be controlled by the panel control andthe remote hand control will not function.


25/92

OM-2240 Page 19

4-8. Gas Connections

802 452

1 Gas Fitting

Fittings have 5/8-18 right-handthreads (3/8-19 BSPP on CE units).

2 Cylinder Valve

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

3 Regulator/Flowmeter4 Flow Adjust

Typical flow rate is 15 cubic feet perhour (7.1 liters per minute).

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

Tools Needed:

3 24

1

11/16, 1-1/8 in, (21, 29 mm)

4-9. TIG HF Impulse/ Lift-ArcConnections

803 430-a

Turn off power before mak-ing connections.

1 Electrode Weld OutputTerminal

Connect TIG torch to weld outputterminal labeled Electrode.

2 Gas Out Connection

Connect torch gas hose to gas outfitting.

3 Work Weld Output TerminalConnect work lead to weld outputterminal labeled Work.

4 Remote 14 Receptacle

Connect desired remote control toRemote 14 receptacle.

5 Gas In Connection

Connect gas hose from gas supplyto gas in fitting.

Tools Needed:

11/16 in, (21 mm)

5

3

4

21


26/92

OM-2240 Page 20

4-10. Stick Connections

803 429-a

Turn off power before mak-ing connections.

1 Electrode Weld OutputTerminal

Connect electrode holder to weldoutput terminal labeled Electrode.

2 Work Weld Output Terminal

Connect work lead to weld output

terminal labeled Work.3 Remote 14 Receptacle

If desired, connect remote controlto Remote 14 receptacle (see Sec-tion 4-7).

1

2

3

4-11. Electrical Service Guide

Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC.If actual input voltage is outside this range, unit may not operate according to

specifications.

NOTE

Single-Phase,100% Duty

Cycle

Single-Phase,60% Duty

Cycle

Three-Phase, 60% DutyCycle

Input Voltage 115 230 230 400 460

Input Amperes At Rated Output 28 20 12.3 7.6 6.0

Max Recommended Standard Fuse Rating In Amperes1

Normal Operating2 35 30 20 10 10

Min Input Conductor Size In AWG/Kcmil 10 12 14 14 14

Max Recommended Input Conductor LengthIn Feet (Meters) 57 (17) 79 (24) 102(31)308(94)

407(124)

Min Grounding Conductor Size In AWG/Kcmil 10 12 14 14 14

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time delay fuse. Time delay fuses are UL class RK5.2 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

above). Failure to follow these fuse and circuit breaker recommendations could create an electrical shock or fire hazard.


27/92

OM-2240 Page 21

2/04 - Ref. 802 136-A / 803 428-A

Installation must meet all Nationaland Local Codes have only quali-fied persons make this installation.

Disconnect and lockout/tagout in-put power before connecting inputconductors from unit.

Always connect green or green/yellow conductor to supplygrounding terminal first, and never

to a line terminal. The Auto-Line circuitry in this unit au-

tomatically adapts the power sourceto the primary voltage being applied.Check input voltage available at site.This unit can be connected to any in-put power between 120 and 460 VACwithout removing cover to relink thepower source.

For Three-Phase Operation

1 Input Power Cord.2 Disconnect Device (switch shown in

the OFF position)3 Green Or Green/Yellow Grounding

Conductor4 Disconnect Device Grounding

Terminal5 Input Conductors (L1, L2 And L3)6 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1, L2, and L3to disconnect device line terminals.

7 Overcurrent Protection

Select type and size of overcurrent protec-tion using Section 4-11(fused disconnectswitch shown).

Close and secure door on disconnectdevice. Remove lockout/tagout device,and place switch in the On position.

= GND/PE Earth Ground

L1

2

1

L2

L3

3

3

4

5

6

7

Tools Needed:

4-12. Connecting Three-Phase Input Power


28/92

OM-2240 Page 22

4-13. Connecting Single-Phase Input Power

2/04 - Ref. 802 136-A / 803 428-A

Installation must meet all Nationaland Local Codes have only quali-fied persons make this installation.

Disconnect and lockout/tagout in-put power before connecting inputconductors from unit.

Always connect green or green/yellow conductor to supplygrounding terminal first, and neverto a line terminal.

The Auto-Line circuitry in this unit au-tomatically adapts the power sourceto the primary voltage being applied.Check input voltage available at site.This unit can be connected to any in-put power between 120 and 460 VACwithout removing cover to relink thepower source.

1 Black And White Input Conductor(L1 And L2)

2 Red Input Conductor3 Green Or Green/Yellow Grounding

Conductor4 Insulation Sleeving

5 Electrical TapeInsulate and isolate red conductor asshown.6 Input Power Cord.7 Disconnect Device (switch shown in

the OFF position)8 Disconnect Device Grounding

Terminal9 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1 and L2 todisconnect device line terminals.

10 Overcurrent ProtectionSelect type and size of overcurrent protec-tion using Section 4-11(fused disconnectswitch shown).

Close and secure door on disconnectdevice. Remove lockout/tagout device,and place switch in the On position.

1

6

54

2

7

6

L1L2

1

=GND/PE Earth Ground

3

3

1

8

9

10

Tools Needed:


29/92

OM-2240 Page 23

SECTION 5 OPERATION

Section 5 in this manual covers operation of all models of 200 and 300 ampereinverter based TIG machines. Features and options referenced may not beavailable on your machine. Verify the model you have before using this section.

NOTE

207 694-A / 802 452

12

For all front panel switch pad controls:

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

NOTE:Green on nameplate indicates a TIGfunction, Gray indicates a Stick function.

1 Encoder Control

Use encoder control in conjunction with appli-cable front panel function switch pads tochange values for that function. See Section5-2.

2 Ammeter And Parameter Display

See Section 5-4.

3 Voltmeter

See Section 5-5.

4 Polarity Control

See Section 5-6.

5 Process Controls

See Section 5-7.

6 Output Controls

See Section 5-8.

7 Pulser Controls (DX AndLX Models)

See Section 5-9.

8 Sequencer Controls (DX, LXAnd All CE Models)

See Section 5-10.

9 Adjust Controls

See Section 5-11.

10 AC Waveshape Control

See Section 5-12.

11 Amperage And Spot Time Control

For Amperage control, see Section 5-3.

For Spot Time control, see Section 5-13.

12 Power Switch

Use switch to turn unit On/Off.

5-1. Controls

123

4 5

11

86 7 9 10


30/92

OM-2240 Page 24

5-2. Encoder Control

1 Encoder Control

Use control in conjunction with ap-plicable front panel function switchpad to set values for that function.

1

5-3. Amperage Control

1 A (Amperage Control)2 Encoder Control3 Ammeter

See Section 5-16 for Amperagecontrol range.

Press Amperage switch pad andturn Encoder control to set weldamperage. Weld amperage settingis also peak amperage when Pulserfunction is active (see Section 5-9).1

2

3

Or Or

5-4. Ammeter And Parameter Display

1 Ammeter

Displays actual amperage whilewelding. Meter also displays preset

parameters for any of the followingunits of measure when they are ac-tive: amperage, time, percentage orfrequency. The correspondingLED, located directly below the am-meter, will also illuminate.

1


31/92

OM-2240 Page 25

5-5. Voltmeter

1 Volt Meter

Displays output or open circuit volt-age. If output is off, the voltmeter willdisplay a series of three dashes(-). Open circuit voltage is dis-played if power is on and output isavailable.

1

5-6. Polarity Control (DynastyModels Only)

1 Polarity Control

Press switch pad until desired LEDis illuminated.

DC - Machine is set to DCEN (directcurrent electrode negative) for TIGwelding, and to DCEP (direct cur-rent electrode positive) for Stickwelding.

AC - Use AC (alternating current)for TIG and Stick welding.1


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5-7. Process Control

1 Process Control

Press switch pad until desired pro-cess LED is illuminated:

TIG HF Impulse- When selected,a pulsed HF (non-contact) (seeSection11-3) arc starting method isactivated. This method can be usedwith either AC or DC TIG welding.Make connections according to

Section 4-9.TIG Lift-Arc- When selected, isan arc starting method in which theelectrode must come in contactwith the workpiece to initiate an arc(see Section 11-3). This methodcan be used with either AC or DCTIG welding. Make connections ac-cording to Section 4-9.

Stick (SMAW)- This method canbe used with either AC or DC Stickwelding. Make connections ac-cording to Section 4-10.

1

5-8. Output Control

1

1 Output ControlPress switch pad until desired param-eter LED is illuminated.

RMT STD (Remote Standard)

Application: Use Remote Trigger(Standard) when the operator desiresto use a foot pedal or finger amperagecontrol (see Section 6-2A).

NOTE: When a foot or finger remotecurrent control is connected to thewelding power source, initial amps,initial slope, final slope, and final amps

are controlled at the remote control,not at the welding power source.

NOTE: If On/Off only type trigger isused, it must be a maintained switch.All Sequencer functions become ac-tive, and must be set by the operator.

RMT 2T HOLD

Application: Use Remote TriggerHold (2T) when long extended weldsare made. Remote Trigger Hold (2T)can help to reduce operator fatigue.

If a foot or finger current control is con-nected to the welding power source,

only trigger input is functional (seeSection 6-2B).

NOTE: This switch function can be re-configured for 4T, 4T Momentary, MiniLogic, or Spot control See Section6-2C)

ON

Output will energize two seconds afterbeing selected.

Application:Use Output On for Stick(SMAW) welding, or for Lift-Arc with-out the use of a remote control (seeSection 6-2H).


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1 Pulser Control

Pulsing is available only while usingthe TIG process, it cannot be se-lected if the Stick process (see Sec-tion 5-7) is active. Controls can be ad-justed while welding.

Press switch pad to enable pulser.

ON- When illuminated, this LED in-dicates the pulser is on.

Press switch pad until desired pa-rameter LED is illuminated.

To turn Pulser off, press and releaseswitch pad until the On LED turns off.

2 Encoder Control3 Ammeter

Turn encoder (see Section 5-2) to se-lect appropriate value for active pulseparameter. Value selected is shownon the ammeter (see Section 5-4).Also, the ammeter LED for the corre-sponding unit of measure (%, A, s,Hz) of the active parameter will be il-luminated.

See Section 5-16for all Pulser pa-rameter ranges.

PPS (Pulses Per Second or PulseFrequency) - Control is used to de-termine appearance of weld bead.

PEAK t - The percentage of eachpulse cycle that can be spent at thepeak amperage level.

BKGND A(Background Amps) - UseBackground Amps control to set thelow pulse of the weld amperage,which cools the weld puddle and af-fects overall heat input. BackgroundAmps is set as a percentage of peakamperage.

4 Pulsed Output Waveforms

Example shows affect changing thePeak Time control has on the pulsedoutput waveform.

NOTE:Peak amperage is set usingthe Amperage control (see Section5-3). Peak amperage is the highestwelding amperage allowed to occurin the pulse cycle. Weld penetrationvaries directly with peak amperage.

Application:

Pulsing refers to the alternating rais-ing and lowering of the weld output ata specific rate. The raised portions ofthe weld output are controlled inwidth, height, and frequency, formingpulses of weld output. These pulsesand the lower amperage level be-tween them (called the backgroundamperage) alternately heat and coolthe molten weld puddle. The com-bined effect gives the operator bettercontrol of penetration, bead width,crowning, undercutting, and heat in-put. Controls can be adjusted whilewelding.

Pulsing can also be used for filler ma-terial addition technique training.

5-9. Pulser Control (DX And LX Models)

1

3

2

Peak AmpBkg AmpBalanced

More TimeAt Peak

Amperage

More TimeAt

BackgroundAmperage

Pulsed Output WaveformsPercent (%) Peak

Time Control Setting

(50%)

(80%)

(20%)

PPS

4


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5-10. Sequencer Controls (DX, LX And All CE Models)

2

3

1

1 Sequencer Control

Sequencing is available only whileusing the TIG process, but is dis-abled if a remote foot or finger cur-rent control is connected to the Re-mote receptacle while in the RMTSTD mode. Sequencer parameterscannot be selected if the Stick pro-cess (see Section 5-7) is active.

Press switch pad until desired pa-rameter LED is illuminated.


Turn encoder (see Section 5-2) toset appropriate value for active se-quence parameter. Value selectedis shown on the ammeter (see Sec-tion 5-4). Also, the ammeter LED forthe corresponding unit of measure(A, S) of the active parameter will beilluminated.

See Section 5-16for all Sequencerparameter ranges.

INITIAL A (Initial Amperage) - Use

control to select a starting amper-age that is different from the weldamperage.

Application:

Initial Amperage can be used whileGTAW welding to assist in preheat-ing cold material prior to depositingfiller material, or to ensure a softstart.

INITIAL t (Initial Time)(LX ModelsOnly) -Press control again and turnEncoder to select amount of timethat is needed at the beginning ofthe weld.

INITIAL SLOPE t (Initial SlopeTime) Use control to select amountof time that it takes to slope up/down from initial amperage to weldamperage. To disable, set to 0.

4 Amperage Switch Pad

Weld Time (LX Models Only) -Press Amperage switch pad twice.Set desired length of weld time.

FINAL SLOPE t (Final Slope Time)- Use control to select amount oftime that it takes to slope up/downfrom weld amperage to final amper-age. To disable, set to 0.

Application:

Final Slope should be used whileGTAW welding materials that arecrack sensitive, and/or the operatorwants to eliminate the crater at theend of the weld.

FINAL A (Final Amperage) - Usecontrol to select amperage to whichweld amperage has sloped up/down to.

FINAL t (Final Time)(LX ModelsOnly) - Press control again and turnEncoder to select amount of timethat is needed at the end of theweld.

4

Or Or


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5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge)

1 Adjust

Press switch pad until desired functionLED is illuminated.


Turn encoder (see Section 5-2) to set ap-propriate value for active Adjust parame-ter. Value selected is shown on the am-meter (see Section 5-4). Also, the am-meter LED for the corresponding unit ofmeasure (S, %) of the active parameterwill be illuminated.

See Section 5-16for all Adjust parame-ter ranges.

PREFLOW - If the TIG HF process is ac-tive (see Section 5-7) and Preflow isshown on the control panel, use controlto set length of time gas flows before arcinitiation. To set Preflow time for modelsthat do not have Preflow Time control onthe front panel, see Section 5-15.

Application: Preflow is used to purgethe immediate weld area of atmosphere.Preflow also aids in consistent arc starts.

POST FLOW - If the TIG process is ac-tive (see Section 5-7), use control to setlength of time gas flows after weldingstops.

Application:

Postflow is required to cool tungsten andweld, and to prevent contamination oftungsten and weld. Increase postflowtime if tungsten or weld are dark in ap-pearance.

DIG - If the DC Stick process is active(see Section 5-7), use control to setamount of DIG. When set at 0, short-cir-cuit amperage at low arc voltage is thesame as normal welding amperage.

When setting is increased, short-circuitamperage at low arc voltage increases.

Application:

Control helps arc starting or making ver-tical or overhead welds by increasingamperage at low arc voltage, and re-duces electrode sticking while welding.

PURGE- While in the TIG process (seeSection 5-7), to activate the gas valveand start the purge function, push andhold the Adjust switch pad for the desiredamount of purge time. To set from 1 to 50seconds of additional purge time, contin-u

MIller Dynasty 200 DX User Manual

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