Miller Syncrowave 250dx

7/25/2019 Miller Syncrowave 250dx

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Visit our website at

www.MillerWelds.com

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Arc Welding Power Source

OM-359 196 831NMarch 2003

Syncrowave 250 DX

And Non-CE Models


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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 orindividual 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 welding

equipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

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

From Miller to You

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

GMAW, and GMAW-P.


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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 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Symbols And Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Selecting A Location 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Dimensions And Weights 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Duty Cycle And Overheating 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5. Volt-Ampere Curves 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6. Weld Output Terminals And Selecting Cable Sizes 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Remote 14 Receptacle Information 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8. Automation 10-Pin Connection (Optional) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle 19. . . . . . . . . . . . . . . . . . . . .3-10. TIG Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) 20. . . . .3-12. Front Panel Display For TIG AC 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13. Stick Connections 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 26. . . . . . . . . . . . . . .3-15. Front Panel Display For Stick AC 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Electrical Service Guide 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17. Placing Jumper Links 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18. Connecting Input Power 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 OPERATION 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Controls 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Output Selector Switch 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Process Control 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Amperage Control 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Output Control 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (Requires

Optional Sequence Controls) 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control 40. . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Selecting TIG Starting Characteristics 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Start Mode 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Meters 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11. Amperage Adjustment Control 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Balance/DIG Control 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13. Preflow Time Control 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14. Postflow Time Control 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15. Pulse Controls (Optional) 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16. Sequence Controls (Optional) 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17. Initial Time Control And Initial Amperage Control 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18. Final Slope Control And Final Amperage Control 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Continued)

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

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


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TABLE OF CONTENTS4-19. Spot Time Control 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20. Timer/Cycle Counter 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21. Resetting Unit To Factory Default Settings (All Models) 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 MAINTENANCE & TROUBLESHOOTING 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Circuit Breaker CB1 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Adjusting Spark Gaps 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Voltmeter/Ammeter Help Displays 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Troubleshooting 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 ELECTRICAL DIAGRAM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 HIGH FREQUENCY 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Welding Processes Requiring High Frequency 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Incorrect Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Correct Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DCOR AC WELDING 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 658-2. Preparing Tungsten Electrode For Welding 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 GUIDELINES FOR TIG WELDING (GTAW) 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Positioning The Torch 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Torch Movement During Welding 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3. Positioning Torch Tungsten For Various Weld Joints 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 STICK WELDING (SMAW) GUIDELINES 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 PARTS LIST 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY


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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: Syncrowave 250DXconforms 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 609741(November 1997 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 Iseo20098 San GiulianoMilanese, Italy

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


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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_7/02

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 1-4. 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 matsor 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. 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 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 ortorch.

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 Safety

Standards.


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OM-359 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 system isproperly 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 driverolls.

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, andcommunicat ions 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 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.


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1-4. 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).

1-5. 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 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 1 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

som _nd_fre 7/02

1-1. 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.

1-2. 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 14.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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1-3. 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 antistatiques

pour 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 l installation.

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

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez dis-tance.

Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.


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1-4. 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).

1-5. 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.


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SECTION 2 DEFINITIONS

2-1. 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 shockby insulating 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

197 310-A


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2-2. Torch/Cable Holder Label

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Electric shock from wiring cankill.

3 Do not operate unit or reachinside when torch/cableholder is removed.

4 Do not exceed 25 lb (12.4 kg)

maximum load on gun/cableholder or holder may break.

1 3

2

2-3. Weld Cable Connection Label

1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.

2 Electric shock from weldingelectrode or wiring can kill.

3 Welding sparks or arcing fromunused electrode can causeexplosion or fire.

4 Do not connect more than oneelectrode cable to any singleweld output terminal.Disconnect cables for processnot in use. Have only onewelding circuit (process)connected at any given time

never two.

1 2 3

4


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OM-359 Page 11

2-4. Symbols And Definitions

Some symbols are found only on CE products.NOTE

AAmperes PanelLocal

Gas Tungsten ArcWelding (GTAW)

Shielded Metal ArcWelding (SMAW)

V Volts Do Not SwitchWhile Welding Arc Force (DIG) Background Amps

Output Circuit Breaker Remote Temperature

Protective Earth(Ground) Alternating Current

High Frequency -Start Input

Postflow Timer Preflow TimerHigh Frequency -

Continuous

Gas (Supply) Gas Input Gas OutputIncrease/Decrease

Of Quantity

On Off Percent Direct Current

Balance Control Maximum CleaningMaximum

Penetration Electrode Positive

ElectrodeNegative Final Slope Meter Single-Phase

U0 Rated No LoadVoltage (Average) U1 Primary Voltage U2 Conventional LoadVoltage Line Connection

I1 Primary Current I2 Rated WeldingCurrent X Duty Cycle 1 1Single-Phase

Combined AC/DCPower Source

IP Degree OfProtection I1eff Maximum EffectiveSupply Current I1max Rated MaximumSupply Current Hz Hertz

Electrode Work Thickness Gauge Spark Gap

S Seconds Final Amperage Initial Time Initial AmperagePulse Percent On

Time Spot Time Lift-Arc 4T4 Step Trigger Op-eration Sequence

Trigger Hold Pulser On-Off Pulse Frequency


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OM-359 Page 12

SECTION 3 INSTALLATION

OR

Location And Airflow

Falling Unit Can CauseInjury.

Use lifting eye to lift unit only,NOT running gear, gascylinders, or any otheraccessories.

Use equipment of adequatecapacity to lift and supportunit.

If using lift forks to move unit,be sure forks are long enoughto extend beyond oppositeside of unit.

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Rating Label

Use rating label to determine inputpower needs.

4 Line Disconnect Device

Locate unit near correct input pow-er supply.

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

Be careful when placing ormoving unit over unevensurfaces.

3-1. Selecting A Location

1

2

Movement

Ref. ST-117 264-C / ST-802 455-C

4

1

3

18 in (460 mm)

18 in (460 mm)


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OM-359 Page 13

3-2. Dimensions And Weights

A Dimensions

D Height 33-1/4 in (845 mm)

CB

C Width 22-1/2 in (572 mm)

GLength 25 in (635 mm)

A 25 in (635 mm)

EFront

B 1-25/64 in (35 mm)

FC 1-5/8 in (41 mm)

D 20-5/8 in (524 mm)

E 19-15/16 (506 mm)

F 22-1/4 (565 mm)

Ref. 207 559H 8 Holes G 1-5/32 in (30 mm)

H 1/2 in (13 mm) Dia

Weight

389 lbs (176 kg)

3-3. Specifications

Amperes Input at AC Balanced RatedLoad Output, 60 Hz, Single-Phase

a eWelding Output PFC** 200V 230V 460V 575V KVA KW

mperageRange

axOCV

NEMA Class I (40)

200 Amperes, 28Volts AC, 60% DutyCycle

NoPFC 88*3.377

*2.838

*1.531

*1.117.6*.59

8.6*.29

5 310A 80V

NEMA Class I (40) 200 Amperes, 28

Volts AC, 60% DutyCycle

WithPFC

60

*55.3

52

*49.5

26

*24.5

21

*19.6

12.06

*11.2

8.11

*.395 310A 80V

NEMA Class II (40) 250 Amperes, 30


NoPFC

110

*3.3

96

*2.8

48

*1.5

38

*1.1

21.98

*.59

11.76

*.295 310A 80V



WithPFC

82

*55.3

71

*49.5

35

*24.5

28

*19.6

16.32

*11.2

11.81

*1.935 310A 80V

*While idling

**Power Factor Correction


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OM-359 Page 14

3-5. Specifications(continued)

Amperes Input at AC Balanced RatedLoad Output, 50/60 Hz, Single-Phase


mperageRange

axOCV



NoPFC

82

*3.0

45

*1.6

41

*1.4

35

*1.2

17.6

*.59

8.6

*.295 310A 80V



WithPFC

61

*45.9

34

*25.1

31

*22.8

26

*23.2

12.06

*11.2

8.11

*.395 310A 80V



NoPFC

100

*3.0

55

*1.6

50

*1.4

42

*1.2

21.98

*.59

11.76

*.295 310A 80V



WithPFC

81

*45.9

44

*25.1

40

*22.8

34

*23.2

16.32

*11.2

11.81

*1.935 310A 80V

*While idling


Amperes Input at AC Balanced RatedLoad Output, 50 Hz, Single-Phase


mperageRange

axOCV



NoPFC

80

*3.3

69

*2.8

35

*1.5

28

*1.1

15.9

*.59

7.4

*.295 310A 80V

NEMA Class I (40)

175 Amperes, 27Volts AC, 60% DutyCycle

WithPFC

52

*55.3

45

*49.5

22

*24.5

18

*19.6

10.3

*11.2

7.3

*.39 5 310A 80V



NoPFC

101

*3.3

88

*2.8

44

*1.5

35

*1.1

20.2

*.59

10.2

*.295 310A 80V



WithPFC

74

*55.3

64

*49.5

32

*24.5

26

*19.6

14.7

*11.2

10.1

*1.935 310A 80V

*While idling



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OM-359 Page 15

3-4. Duty Cycle And Overheating

Duty Cycle is the percentage of 10minutes that the unit can weld atrated load without overheating.

If unit overheats, output stops, frontpanel voltmeter/ammeter displaysa HLP3 or HLP5 message (seeSection 5-4), and cooling fans run.Wait fifteen minutes for unit to cool.Reduce amperage or duty cycle be-fore welding.

Exceeding duty cycle candamage unit and void war-ranty.

Overheating0

15

A

ORReduce Duty CycleMinutes

duty1 4/95 / SB-116 198

4 Minutes Welding 6 Minutes Resting

40% Duty Cycle At 250 Amperes

6 Minutes Welding 4 Minutes Resting

60% Duty Cycle At 200 Amperes


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OM-359 Page 16

194 385-A / 194 384-A

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

3-5. Volt-Ampere Curves

Non Ce Models

Ce Models

205 631 / 205 632


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OM-359 Page 17

3-6. Weld Output Terminals And Selecting Cable Sizes

ARC WELDING can cause Electromagnetic Interference.

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 electronic equipment. Be sure this welding machine is installedand grounded according to this manual. If interference still occurs, the user must take extra measures such as movingthe welding machine, using shielded cables, using line filters, or shielding the work area.

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

Turn off power beforeconnecting to weld out-put terminals.

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

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

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

ElectrodeWork 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

Ref. ST-801 972-C 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere*Select weld cable size for pulsing application at peak amperage value.. S-0007-D

3-7. Remote 14 Receptacle Information

Turn off power before

Socket* Socket Informationconnec ng o recep ac e.

24 VOLTS DC A Contactor control 24 volts dc.

A JB K I

OUTPUTCONTACTOR

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

C L N H

D M GE F

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

REMOTEOUTPUT

D Remote control/feedback circuit common.

CONTROL E 0 to +10 volts dc input command signal fromremote control.

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

Ref. ST-801 972-C GND K Chassis common.

*The remaining sockets are not used.


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OM-359 Page 18

3-8. Automation 10-Pin Connection (Optional)

Socket Socket Information For 10-Pin Receptacle RC3

F ED

A Start/Stop

J

B

G

I

CH

B Gas

AC Output disabled

D Chassis ground

Turn off power beforeconnecting to receptacle

E Final slope collector

F Final slope emitter

G Pulse lockout collector

Ref. ST-801 972-C H Pulse lockout emitter

I Valid arc collector

J Valid arc emitter

Definitions Of Inputs And Outputs

Inputs

A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100ms, butless than 3/4 seconds) starts and stops weld output.

B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initia-tion.

C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins totime out, and will be displayed on the meters.

Outputs

Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30VDC.

Final Slope - output is on when in Final Slope.

Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10Hz.

Arc On - output is on when the contactor is on and there is less than 50 load volts.


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OM-359 Page 19

3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle

Ref. ST-801 972-C / Ref. ST-801 973 / Ref. ST-157 858

Turn Off power before con-necting to receptacle.

1 Gas Valve In Fitting

Located on rear of unit.

2 Gas Valve Out Fitting

Fittings have 5/8-18 right-handthreads.

3 Cylinder Valve

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

4 Regulator/Flow Gauge

Connect regulator/flow gauge togas cylinder.

Connect customer supplied gashose between regulator/flow gaugeand gas in fitting.

5 Flow Adjust

Typical flow rate is 20 cfh (cubic feetper hour).

6 115 V 15 Amp AC Receptacle

Receptacle is protected from over-load by circuit breaker CB1 (see

Section 5-2).

5

1

6

4

2

5/8, 3/4, 1-1/8 in

Tools Needed:

3

Front View Rear View

3-10. TIG Connections

802 734-C

Turn Off power before mak-ing connections.

1 Gas In ConnectionConnect gas hose from gas supplyto gas in fitting.

2 Output Selector Switch (SeeSection 4-2)

Switch is shown in DCEN (directcurrent electrode negative) positionfor TIG HF Impulse DCEN welding.For front panel control dispay, seeSection 3-11. For TIG AC welding,place switch in AC position (seeSection 4-2). For TIG AC front pan-el control dispay, see Section 3-12.

3 Work Weld Output Terminal

Connect work lead to work weld

output terminal.4 Remote 14 Receptacle

Connect desired remote control toRemote 14 receptacle.

5 Electrode Weld OutputTerminal

Connect TIG torch to electrodeweld outout terminal.

6 Gas Out Connection

Connect torch gas hose to gas outfitting.Tools Needed:

11/16, (21 mm), 3/4 in

1

2

3

45 6


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OM-359 Page 20

3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)

1

1 Front Panel

Correct front panel display for basicTIG HF Impulse DCEN welding.

For all front panel switch padcontrols: press switch pad toturn on light and enable function.

NOTE: Green on nameplate indi-cates a TIG function (see Section4-1 for description of controls).


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OM-359 Page 21

CE Models

1


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OM-359 Page 22

3-12. Front Panel Display For TIG AC

1 Front Panel

Correct front panel display for basicTIG AC welding.


NOTE: Green on nameplate indi-cates a TIG function (see Section4-1 for description of controls).

1


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OM-359 Page 23

CE Models

1


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OM-359 Page 25

3-13. Stick Connections

802 733-C

Turn Off power before mak-ing connections.

1 Work Weld Output Terminal

Connect work lead to work weldoutput terminal.

2 Electrode Weld OutputTerminal

Connect electrode holder to elec-trode weld outout terminal.

3 Remote 14 Receptacle

If desired, connect remote controlto Remote 14 receptacle.

4 Output Selector Switch (SeeSection 4-2)

Switch is shown in DCEP (directcurrent electrode positive) positionfor Stick DCEP welding. For frontpanel control dispay, see Section3-14. For Stick AC welding, placeswitch in AC position (see Section4-2). For Stick AC front panel con-trol dispay, see Section 3-15.

1

Tools Needed:

11/16, (21 mm), 3/4 in

2

3

4


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OM-359 Page 26

3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

1 Front Panel

Correct front panel display for basicStick DCEP welding.


NOTE:Gray on nameplate indicatesa Stick function (see Section 4-1 fordescription of controls).

1


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OM-359 Page 27

CE Models

1


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OM-359 Page 28

3-15. Front Panel Display For Stick AC

1 Front Panel

Correct front panel display for basicStick AC welding.


NOTE:Gray on nameplate indicatesa Stick function (see Section 4-1 fordescription of controls).

1


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OM-359 Page 31

1

3-17. Placing Jumper Links

Ref. ST-801 973-B

Disconnect and lockout/tag-out input power beforeinstalling or moving jumperlinks.

Check input voltage available atsite.

1 Jumper Link Label

Check label only one is on unit.

2 Jumper LinksMove jumper links to match inputvoltage.

Close and secure access door, orgo on to Section 3-18.

3/8 in

Tools Needed:

230 VOLTS 460 VOLTS200 VOLTS

L L L L L L

S-083 566-C2

230 VOLTS

L L

460 VOLTS

L L

S-010 587-B

575 VOLTS

L L


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OM-359 Page 33

SECTION 4 OPERATION4-1. Controls

A. For 200/230/460 Volts And Non CE Units

204 776 / Ref. ST-801 972

Top row of lights in upper left corner are Onfor SMAW. Bottom row are On for GTAW.

Green on nameplate indicates a TIG function,Gray indicates a Stick function.

1 Process Control

See Section 4-3.

2 Amperage Control

See Section 4-4.

3 Output Control

See Section 4-5.

4 Start Mode Control

See Section 4-9.

5 Voltmeter

See Section 4-10

6 AmmeterSee Section 4-10

7 Amperage AdjustmentControl

See Section 4-11.

8 Output Selector Switch

See Section 4-2.

9 Power Switch

Use switch to turn unit Off and On.

10 Postflow Time Control

See Section 4-14.

11 Balance/DIG Control

See Section 4-12.

12 Pulser Controls (Optional)

See Section 4-15.

13 Sequence Controls (Optional)

See Section 4-16.

1 2 3 4 5 6 7

10

11

13

12

9 8


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OM-359 Page 34

B. For CE Units

208 242 / Ref. ST-801 972-C

1 2 3 4 5 6 7

10

11

13

12

Top row of lights in upper left corner are Onfor SMAW. Bottom row are On for GTAW.

Green on nameplate indicates a TIG function,Gray indicates a Stick function.

1 Process Control

See Section 4-3.

2 Amperage Control

See Section 4-4.

3 Output Control

See Section 4-5.

4 Start Mode Control

See Section 4-9.

5 Voltmeter

See Section 4-10

6 Ammeter

See Section 4-10

7 Amperage AdjustmentControl

See Section 4-11.

8 Output Selector Switch

See Section 4-2.

9 Power Switch

Use switch to turn unit Off and On.


See Section 4-14.

11 Balance/DIG Control

See Section 4-12.

12 Pulser Controls (Optional)

See Section 4-15.

13 Sequence Controls (Optional)

See Section 4-16.

98


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OM-359 Page 37

(CE Nameplate)

3

Trigger Hold (2T)

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

Current (A)

Preflow

Initial Amps

Final Slope

Postflow

Push & Release TriggerIn Less Than 3/4 Sec.

Weld Amps

Final Amps

2T Torch Trigger Operation

Push & Release TriggerIn Less Than 3/4 Sec.

3 Trigger Hold

For trigger hold operation, press button totoggle LED to Trigger Hold position.

Torch trigger operation is as shown.

NOTE: When a foot or finger remote con-trol is connected to the welding powersource, only trigger input is functional.

NOTE: Amperage is controlled by the

welding power source.Application: Use Trigger Hold (2T)when long extended welds are made.Trigger Hold (2T) can help to reduce op-erator fatigue.

3


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OM-359 Page 38

4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional SequenceControls)

If unit is equipped with optional SequenceControls (see Section 4-16), 4T triggermethod is available.

4T torch trigger operation is as shown.

While in 4T mode, there is a feature avail-able during the main weld sequence that al-

lows the operator to toggle between weldcurrent and final current without breakingthe arc.

NOTE: When a remote switch is connectedto the welding power source, only trigger in-put is functional. Amperage is controlled bythe welding power source.

Application:

Use 4T trigger method when the functionsof a remote current control are desired, butonly a remote on/off control is available.

Select 4T trigger method according to Sec-tion 4-7.

Current (A)

Preflow

Initial Amps

Final Slope

Postflow

Push & HoldTrigger

ReleaseTrigger

Push & HoldTrigger

ReleaseTrigger

Push & ReleaseTrigger In LessThan 3/4 Sec.

Weld Amps

Final Amps


4T Torch Trigger Operation

If unit is equipped with optional SequenceControls (see Section 4-16), 4T Momen-tary trigger method is available.4T Momentary torch trigger operation is asshown.While in 4T Momentary mode, once the op-erator toggles out of weld current and be-gins final slope, toggling again will breakthe arc and go to postflow.

NOTE: When a remote switch is connectedto the welding power source, only trigger in-put is functional. Amperage is controlled bythe welding power source.

Application:

Use 4T Momentary trigger method whenthe functions of a remote current control aredesired, but only a remote on/off control isavailable.Select 4T Momentary trigger method ac-cording to Section 4-7.

Current (A)

Preflow

Initial Amps

Final Slope

Postflow

Push & ReleaseTrigger


Weld Amps

Final Amps

4T Momentary Torch Trigger Operation




45/90

OM-359 Page 39

Preflow

Initial Amps

Final Slope

Postflow

Weld Amps

Push & HoldTrigger For MoreThan 3/4 Sec.

Release Trigger

Final SlopeRate


Initial Amps



Push & HoldTrigger For MoreThan 3/4 Sec.

Push & HoldTrigger

Mini Logic Operation

If unit is equipped with optional SequenceControls (see Section 4-16), Mini Logic op-eration is available.

Torch trigger operation is as shown.

During Mini Logic welding operation, theweld amperage can be manually changed

from the initial amps level to the main weldamps level by pressing and releasing thetorch trigger in less than 3/4 seconds.

NOTE: When a remote switch is connected

to the welding power source, only trigger in-put is functional. Amperage is controlled by

the welding power source.

Application:This ability to change amper-age levels without either initial slope or finalslope, gives the operator the opportunity toadjust filler metal without breaking the arc.

Select Mini Logic according to Section 4-7.


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OM-359 Page 41

1

(CE Nameplate)

3

= 4T Momentary(See Section 4-6)

= 4T (See Section 4-6)

= Mini Logic (See Section 4-6)

Front Panel

2


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OM-359 Page 42

4-8. Selecting TIG Starting Characteristics

1

2

Use this function to select desired TIG start-ing characteristics.

1 Start Mode2 Power Switch3 Output Selector Switch4 MetersTo select or change TIG starting characteris-tics, proceed as follows: turn Off power.Place Output Selector switch in desired posi-tion (each position, DCEN, AC, or DCEP hasthree applicable start characteristics op-

tions). Push and hold Start Mode button andturn On power. Hold button for approximately

7 seconds (or until software version number__ _ _ _ _-_ clears meters).

The TIG LED and all four Start LEDs will light,and the meters will display [][].

Press Start Mode button again to stepthrough the three start characteristicschoices.Amperage (bottom) meter displaysactive choice = light start, =medium/normalstart, =high/hot start.

Press torch trigger or turn Off power to savesetting.

Application:Select (light/soft start) when welding at lowamperages on thin gauge material.Select (medium/normal start) factory de-fault setting used for most welding applica-tions.Select (high/hot start) when welding athigh amperages on thick materials with alarge diameter tungsten.

3

4


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OM-359 Page 43

23

(CE Nameplate)1 4


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OM-359 Page 44

4-9. Start Mode

1 Start Mode

For SMAW welding, press button to toggleLED to Off position.

For GTAW welding, use control to selectOff for no HF, Lift-Arc, HF for arc startingonly, or continuous HF.

Application:

When Off is selected, use the scratch

method to start an arc for both the SMAWand GTAW processes.

When Lift-Arc is selected, start arc asfollows:

2 TIG Electrode

3 Workpiece

Touch tungsten electrode to workpiece atweld start point, enable output with torchtrigger, foot control, or hand control. Holdelectrode to workpiece for 1-2 sec-

onds, and slowly lift electrode. An arc willform when electrode is lifted.

Shielding gas begins to flow when elec-trode touches work piece.

Normal open-circuit voltage is not presentbefore tungsten electrode touches work-piece; only a low sensing voltage is pres-ent between electrode and workpiece.The solid state output contactor does notenergize until after electrode is touchingworkpiece. This allows electrode to touchworkpiece without overheating, sticking,or getting contaminated.

Application:

Lift-Arc is used for the DCEN GTAW pro-cess when HF Start method is not per-mitted, or to replace the scratch method.

When HF Start is selected, start arc asfollows:

High frequency turns on to help start arcwhen output is enabled. High frequency

turns off when arc is started, and turns onwhenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTAWprocess is required.

When HF Continuous is selected, startarc as follows:

High frequency turns on when output isenergized and remains on for duration ofweld.

Application:

HF Continuous is used when the ACGTAW process is required.

NOTE:Lit LED indicates selected mode.

When Output Selector switch positionchanges, LED may change position,based upon last selection.

NOTE: Some start methods may not beavailable for all processes.

2

1 2SecondsTouch

Do NOT Strike Like A Match!

3

Lift-ArcStart Method

1

(CE Nameplate)

1


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OM-359 Page 45

4-10. Meters

1 Voltmeter

Voltmeter displays average voltage(to the nearest 0.1 V) at the weldoutput terminals.

2 Ammeter

Use meter to preset amperage. Me-ter displays average weld amper-age output of unit to nearest am-pere when welding.

NOTE:Meters are self-calibrating.No adjustment available.

1

2

4-11. Amperage Adjustment Control

1 Amperage Adjustment Control

Use control to adjust amperage,and preset amperage on ammeter(see Section 4-10). This controlmay be adjusted while welding.

For remote amperage control,front panel control setting is themaximum amperage available. Forexample: If front panel control is setto 200 A, the range of the remoteamperage control is 5 to 200 A.

For pulse welding, use AmperageAdjust control to select from 5300amps of peak amperage (see Sec-tion 4-15).

For spot welding, use AmperageAdjust control to select from 5300amps of peak amperage (see Sec-tion 4-19).

(CE Nameplate)

1 1


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OM-359 Page 50

4-14. Postflow Time Control


Use control to set length of time(050 seconds) gas flows afterwelding stops. It is important to setenough time to allow gas to flow un-til after the tungsten and weldpuddle has cooled down.

Application:

Postflow is required to cool tung-

sten and weld, and to prevent con-tamination of tungsten and weld. In-crease postflow time if tungsten orweld are dark in appearance(approximately 1 second per 10ampere of welding current).

(CE Nameplate)

1 1


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OM-359 Page 51

4-15. Pulse Controls (Optional)

1 On/Off Control

Use control to turn pulse functionOn and Off.

2 Background Amps

Use Background Amps control toset the low pulse of the weld am-perage, which cools the weldpuddle and affects overall heat in-put. Background Amps is set as a

percentage of peak amperage.3 Pulse Frequency

Ranges from 0.2510.0 pps(pulses per second). Control isused to determine appearance ofweld bead.

4 Peak Time

A range of 595% of each pulsecycle can be spent at the peakamperage level.

Peak amperage (5310 amps), isset with the Amperage Adjust-ment control (see Section 4-1).Peak amperage is the highestwelding amperage allowed to oc-

cur in the pulse cycle. Weld pene-tration varies directly with peakamperage.

5 Pulsed Output Waveforms

Example shows affect changingthe Peak Time control has on thepulsed output waveform.

Application:

Pulsing refers to the alternatingraising and lowering of the weldoutput at a specific rate. Theraised portions of the weld outputare controlled in width, height,and frequency, forming pulses ofweld output. These pulses and

the lower amperage level be-tween them (called the back-ground amperage) alternatelyheat and cool the molten weldpuddle. The combined effectgives the operator better controlof penetration, bead width,crowning, undercutting, and heatinput. Controls can be adjustedwhile welding.

Pulsing can also be used for fillermaterial addition techniquetraining.

NOTE: Function is enabled,when LED is lit.

Peak Amp

Bkg AmpBalanced

More TimeAt PeakAmperage

More Time AtBackgroundAmperage

Pulsed Output WaveformsPercent (%) PeakTime Control Setting

(50%)

(80%)

(20%)

PPS

5

(CE Nameplate)

1 2 3 4

1 2 3 4


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4-17. Initial Time Control And Initial Amperage Control

1 Initial Time Control

Indicator light is on when InitialTime control function is active.

NOTE: Initial Sequence controlfunction is inactive when Spot Timefunction is active.

Use control to select 015 secondsof start time.

2 Initial Amperage ControlIndicator Light is on when Initial Se-quence control function is active.

NOTE: Initial Amperage controlfunction is inactive when Spot Timefunction is active.

Use control to select a starting am-perage (5310 amps) that is differ-ent from the weld amperage. Note:Initial Amperage can be used withor without a remote control (InitialAmperage and Initial Time controlsettings will override a remote con-trol device).

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 Amperage can also beused for SMAW to ensure a moreconsistent arc strike.

NOTE: Function is enabled, whenLED is lit.

(CE Nameplate)

1

2

1

2


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4-20. Timer/Cycle Counter

1 Amperage Control2 Output Control (Contactor)

To read timer/cycle counter, hold Amper-age and Output (contactor) buttons whileturning on power.

3 Timer Display

The hours and minutes are displayed onthe volt and amp meters for the first fiveseconds, and are read as 1, 234 hoursand 56 minutes.

4 Cycle Display

The cycles are displayed on the volt andamp meters for the next five seconds,and are read as 123, 456 cycles.

2

(CE Nameplate)

3

4

2

1

1


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OM-359 Page 56

4-21. Resetting Unit To Factory Default Settings (All Models)

1 2 3 4

5

1 Process Control2 Amperage Control3 Output Control4 Start Control

5 Power Switch

To reset all welding power source functionsto original factory settings, turn power off.Push and hold the Process, Amperage,

Output and Start controls and turn On pow-er. Hold switch pads for approximately 7seconds (or until software version number

_ _ _ _ _ _-_clears meters).


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Miller Syncrowave 250dx

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