miller thunderbolt welder

8/12/2019 miller thunderbolt welder

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225 AC, 225/150 AC/DC, And 300/200 AC/DC

OM-316 087 083T201004

Visit our website at

www.MillerWelds.com

File: Stick(SMAW)

Processes

Stick (SMAW) Welding

Description

Arc Welding Power Source

225 AC Models:

225/150 AC/DC Models:

300/200 AC/DC Models:

Thunderbolt XL


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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 or individual specification 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 Quality SystemStandard.

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

From Miller to You

Mil_Thank 200909


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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. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utiliss 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7. . . . . .2-4. Proposition californienne 65 Avertissements 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de scurit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Informations relatives aux CEM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Symbols And Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Duty Cycle Charts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Volt-Ampere Curves 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Serial Number And Rating Label Location 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Selecting A Location 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Installing Electrode Holder And Work Clamp 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Weld Output Cables 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8. Electrical Service Guide 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Connecting Input Power 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE & TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Lubricating Shunt Block And Anti-Noise Adjustment 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Reinstalling Amperage Adjustment Indicator 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAMS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 STICK WELDING (SMAW) GUIDELINES 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 PARTS LIST 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY


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OM-316 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _201003

7

Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICEIndicates statements not related to personal injury.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit is

electrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically 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. Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

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.

Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

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 directly

with a separate cable. Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine. Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will bepresent.

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 prevent

contact with any metal object. Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of inputpower. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

HOT PARTS can burn.

Do not touch hot parts bare handed. Allow cooling period before working on equip-

ment. To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.


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OM-316 Page 2

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 local forced ventilation at the

arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while

wearing 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 while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

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

Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

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

ARC RAYS can burn eyes and skin.

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.

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

Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can

easily 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 can

cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Do not weld where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

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, sparks, and firehazards.

Do not use welder to thaw frozen pipes.

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

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

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

After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.

Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

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

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

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect ImplantedMedical Devices.

Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

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, physical damage, 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 in

use or connected for use. Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders,associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.


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OM-316 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 is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

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 are long enough toextend beyond opposite side of unit.

Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94110) when manu-ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before

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

FLYING SPARKS can injure.

Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with

proper guards in a safe location wearing properface, hand, and body protection.

Sparks can cause fires keep flammables away.

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 injure.

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

rolls.

WELDING WIRE can injure.

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 injure.

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

closed and securely in place.

Have only qualified persons remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.

Reinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.

READ INSTRUCTIONS.

Read and follow all labels and the OwnersManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owners

Manuals, industry standards, and national, state, and localcodes.

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, keep

spark 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 iselectromagnetically compatible.

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

Locate welding operation 100 meters from any sensitive elec-

tronic equipment. Be sure this welding machine is installed and grounded

according to this manual. If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,using line filters, or shielding the work area.


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OM-316 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & 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.

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting,American Welding Society Standard AWS F4.1, from Glob-al Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).National Electrical Code,NFPA Standard 70, from National Fire Protec-tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:www.nfpa.org and www. sparky.org).Safe Handling of Compressed Gases in Cylinders,CGA Pamphlet P-1,from Compressed Gas Association, 4221 Walney Road, 5th Floor,Chanti lly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:800-463-6727, website: www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion,ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork,NFPA Standard 51B, from National Fire Protection Association,Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.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 15250-7954(phone: 1-866-512-1800) (there are 10 OSHA Regional Officesphone for Region 5, Chicago, is 312-353-2220, website:www.osha.gov).U.S. Consumer Product Safety Commission (CPSC), 4330 East WestHighway, Bethesda, MD 20814 (phone: 301-504-7923, website:www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation, The Na-tional Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:www.cdc.gov/NIOSH).

1-6. EMF Information

Electr ic current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, access restrictions for passersby or individual risk assess-ment for welders. All welders should use the following procedures inorder to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using acable cover.

2. Do not place your body between welding cables. Arrange cablesto one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.


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OM-316 Page 5

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

fre_som_2010037

Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.

Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

NOTEIndique des dclarations pas en relation avec des blessurespersonnelles.

Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGERDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECESCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce ma-nuel pour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructionsen matire de scurit indiques ci-dessous ne constituentquun sommaire des instructions de scurit plus compltesfournies dans les normes de scurit numres dans la Sec-tion 2-5. Lire et observer toutes les normes de scurit.

Seul un personnel qualifi est autoris installer, faire fonc-tionner, entretenir et rparer cet appareil.

Pendant le fonctionnement, maintenir distance toutes lespersonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr lasortie. Le circuit dalimentation et les circuits inter-nes de la machine sont galement sous tensionlorsque lalimentation est sur Marche. Dans le modede soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalli-ques en contact avec le fil sont sous tensionlectrique. Un quipement install ou mis la terrede manire incorrecte ou impropre constitue undanger.

Ne pas toucher aux pices lectriques sous tension. Porter des gants isolants et des vtements de protection secs et

sans trous. Sisoler de la pice couper et du sol en utilisant des housses ou

des tapis assez grands afin dviter tout contact physique avec la

pice couper ou le sol. Ne pas se servir de source lectrique courant lectrique dans leszones humides, dans les endroits confins ou l o on risque detomber.

Se servir dune source lectrique courant lectrique UNIQUE-MENT si le procd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savrencessaire, se servir de la fonction de tlcommande si lappareilen est quip.

Dautres consignes de scurit sont ncessaires dans les condi-tions suivantes : risques lectriques dans un environnementhumide ou si lon porte des vtements mouills ; sur des structuresmtalliques telles que sols, grilles ou chafaudages ; en positioncoince comme assise, genoux ou couche ; ou sil y a un risquelev de contact invitable ou accidentel avec la pice souder oule sol. Dans ces conditions, utiliser les quipements suivants,

dans lordre indiqu : 1) un poste souder DC tension constante( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations,lutilisation dun poste souder DC fil tension constante est re-commande. En outre, ne pas travailler seul !

Couper lalimentation ou arrter le moteur avant de procder lin-stallation, la rparation ou lentretien de lappareil. Dverrouillerlalimentationselon la norme OSHA 29 CFR 1910.147 (voir nor-mes de scurit).

Installer le poste correctement et le mettre la terre convenable-ment selon les consignes du manuel de loprateur et les normesnationales, provinciales et locales.

Toujours vrifier la terre du cordon dalimentation. Vrifier etsassurer que le fil de terre du cordon dalimentation est bienraccord la borne de terre du sectionneur ou que la fiche ducordon est raccorde une prise correctement mise la terre.

En effectuant les raccordements dentre, fixer dabord le conduc-teur de mise la terre appropri et contre-vrifier les connexions.

Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgezles contre les tincelles et les pices mtalliqueschaudes.

Vrifier frquemment le cordon dalimentation afin de sassurerquil nest pas altr ou nu, le remplacer immdiatement sil lest.Un fil nu peut entraner la mort.

Lquipement doit tre hors tension lorsquil nest pas utilis.

Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-sante ou mal pisss.

Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement

avec un cble distinct.

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

Ne pas toucher des porte lectrodes connects deux machines

en mme temps cause de la prsence dune tension vide dou-ble. Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-

champ les pices endommages. Entretenir lappareil conform-ment ce manuel.

Porter un harnais de scurit si lon doit travailler au-dessus du sol. Sassurer que tous les panneaux et couvercles sont correctement

en place.

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

Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

Ne pas raccorder plus dune lectrode ou plus dun cble demasse une mme borne de sortie de soudage.


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Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur UNE FOISlalimentation coupe. Arrter les convertisseurs, dbrancher le courant lectrique et

dcharger les condensateurs dalimentation selon les instructionsindiques dans la partie Entretien avant de toucher les pices.

LES PICES CHAUDES peuventprovoquer des brlures.

Ne pas toucher mains nues les partieschaudes.

Prvoir une priode de refroidissement avant dtravailler lquipement.

Ne pas toucher aux pices chaudes, utiliser les outils recomman-ds et porter des gants de soudage et des vtements pais pourviter les brlures.

LES FUMES ET LES GAZ peuventtre dangereux.

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

Eloigner votre tte des fumes. Ne pas respirer les fumes.

lintrieur, ventiler la zone et/ou utiliser une ventilation force auniveau de larc pour lvacuation des fumes et des gaz desoudage.

Si la ventilation est mdiocre, porter un respirateur anti-vapeursapprouv.

Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgrais-seurs.

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

Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur etles rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soitbien ventil, et en portant un respirateur alimentation dair. Lesrevtements et tous les mtaux renfermant ces lments peuventdgager des fumes toxiques en cas de soudage.

LES RAYONS DE LARC peuventprovoquer des brlures dans lesyeux et sur la peau.Le rayonnement de larc du procd de soudaggnre des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brlure

dans les yeux et sur la peau. Des tincelles sont projetes pendant lsoudage.

Porter un casque de soudage approuv muni de verres filtrantsappropri pour protger visage et yeux pour protger votre visageet vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1et Z87.1 numr dans les normes de scurit).

Porter des lunettes de scurit avec crans latraux mme sousvotre casque.

Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissementset les tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

Porter des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

LE SOUDAGE peut provoquer unincendie ou une explosion.Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent

tre projetes de larc de soudure. La projection dtincelles, despices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avecdes objets mtalliques peut provoquer des tincelles, une explosion,un surchauffement ou un incendie. Avant de commencer le soudage,vrifier et sassurer que lendroit ne prsente pas de danger.

Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit les recouvrirsoigneusement avec des protections homologus.

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

Se protger et dautres personnes de la projection dtincelles etde mtal chaud.

Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

Le soudage effectu sur un plafond, plancher, paroi ou sparation

peut dclencher un incendie de lautre ct. Ne pas effectuer le soudage sur des conteneurs ferms tels que

des rservoirs, tambours, ou conduites, moins quils naient tprpars correctement conformment AWS F4.1 (voir les nor-mes de scurit).

Ne soudez pas si lair ambiant est charg de particules, gaz, ou va-peurs inflammables (vapeur dessence, par exemple).

Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur unelongue distance par des chemins inconnus ventuels en provo-quant des risques dlectrocution, dtincelles et dincendie.

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

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

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

Avant de souder, retirer toute substance combustible de vos po-ches telles quun allumeur au butane ou des allumettes.

Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux chaud et avoir de la surveillance et unextincteur proximit.

DES PIECES DE METAL ou DESSALETES peuvent provoquer desblessures dans les yeux.

Le soudage, lcaillement, le passage de la pice la brosse enfil de fer, et le meulage gnrent des tincelles et des particulesmtall iques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

Porter des lunettes de scurit avec crans latraux ou un cranfacial.


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LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort. Fermer lalimentation du gaz protecteur en cas

de non-utilisation. Veiller toujours bien arer les espaces confi-

ns ou se servir dun respirateur dadductiondair homologu.

Les CHAMPS LECTROMAGNTIQUES (CEM)peuvent affecter les implants mdicaux.

Les porteurs de stimulateurs cardiaqueset autres implants mdicaux doivent rester distance.

Les porteurs dimplants mdicaux doivent consulterleur mdecin et le fabricant du dispositif avant de sapprocherde la zone o se droule du soudage larc, du soudagepar points, du gougeage, de la dcoupe plasmaou une opration de chauffage par induction.

LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.

Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endom-mage, elle peut exploser. Du fait que les bouteillesde gaz font normalement partie du procd de

soudage, les manipuler avec prcaution.

LES BOUTEILLES peuvent explosersi elles sont endommages.

Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

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

Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

Ne jamais placer une torche de soudage sur une bouteille gaz.

Une lectrode de soudage ne doit jamais entrer en contact avecune bouteille.

Ne jamais souder une bouteille pressurise risque dexplosion.

Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,tuyaux et raccords convenables pour cette application spcifique ;les maintenir ainsi que les lments associs en bon tat.

Dtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

Le couvercle du dtendeur doit toujours tre en place, sauf lorsque

la bouteille est utilise ou quelle est relie pour usage ultrieur. Utiliser les quipements corrects, les bonnes procdures et suffi-

samment de personnes pour soulever et dplacer les bouteilles.

Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scu-rit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OUDEXPLOSION. Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables. Ne pas installer lappareil proximit de pro-

duits inflammables. Ne pas surcharger linstallation lectrique sassurer que

lalimentationest correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LQUIPEMENT peutprovoquer des blessures. Utiliser lanneau de levage uniquement pour

soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

Tenir lquipement (cbles et cordons) distance des vhiculesmobiles lors de toute opration en hauteur.

Suivre les consignes du Manuel des applications pour lquationde levage NIOSH rvise (Publication N94110) lors du levagemanuelle de pices ou quipements lourds.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT. Prvoir une priode de refroidissement ; res-

pecter le cycle opratoire nominal. Rduire le courant ou le facteur de marche

avant de poursuivre le soudage. Ne pas obstruer les passages dair du poste.

LES TINCELLES PROJETESpeuvent provoquer des blessures.

Porter un cran facial pour protger le visage etles yeux.

Affter llectrode au tungstne uniquement lmeuleuse dote de protecteurs. Cett

manuvre est excuter dans un endroit srlorsque lon porte lquipement homologu dprotection du visage, des mains et du corps.

Les tincelles risquent de causer un incendie loigner toute sub-stance inflammable.

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

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

Utiliser des pochettes et des botes antista-tiques pour stocker, dplacer ou expdier descartes de circuits imprimes.


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Les PICES MOBILES peuventcauser des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures. Ne pas appuyer sur la gchette avant den

avoir reu linstruction. Ne pas diriger le pistolet vers soi, dautres

personnes ou toute pice mcanique enengageant le fil de soudage.

Les PICES MOBILES peuventcauser des blessures. Sabstenir de toucher des organes mobiles tels

que des ventilateurs. Maintenir ferms et verrouills les portes,

panneaux, recouvrements et dispositifs deprotection.

Lorsque cela est ncessaire pour des travaux dentretien et dedpannage, faire retirer les portes, panneaux, recouvrements

ou dispositifs de protection uniquement par du personnel qua-lifi. Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.

Lire et appliquer les instructions sur lestiquettes et le Mode demploi avant linstal-lation, lutilisation ou lentretien de lappareil.Lire les informations de scurit au dbut dumanuel et dans chaque section.

Nutiliser que les pices de rechange recommandes par leconstructeur.

Effectuer lentretien en respectant les manuels dutilisation, lesnormes industrielles et les codes nationaux, dtat et locaux.

LE RAYONNEMENT HAUTEFRQUENCE (H.F.) risque deprovoquer des interfrences.

Le rayonnement haute frquence (H.F.) peutprovoquer des interfrences avec les qui-pements de radionavigation et de com-munication, les services de scurit et les ordi-nateurs.

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

tion. Lutilisateur est tenu de faire corriger rapidement par un lectricien

qualifi les interfrences rsultant de linstallation. Si le FCC signale des interfrences, arrter immdiatement lap-

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

sources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

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

Veiller ce que tout lquipement de la zone de soudage soitcompatible lectromagntiquement.

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

Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

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

En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-

bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent des

cancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

Ce produit contient des produits chimiques, notamment duplomb, dont ltat de Californie reconnat quils provoquent

des cancers, des malformations congnitales ou dautresproblmes de procration. Se laver les mains aprsutilisation.

Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

Pour les moteurs diesel :

Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.


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2-5. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes,ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting,American Welding Society Standard AWS F4.1, de GlobalEngineering Documents (tlphone : 1-877-413-5184, site internet :www.global.ihs.com).National Electrical Code, NFPA Standard 70, de National Fire Protec-tion Association, Quincy, MA 02269 (tlphone : 800-344-3555, site

Internet : www.nfpa.org et www.sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, de Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone :800-463-6727, site internet : www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion,ANSI Standard Z87.1, de American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (tlphone : 212-642-4900,site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association,P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000,site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for GeneralIndustry, Title 29, Code of Federal Regulations (CFR), Part 1910,Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing

Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureauxrgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, siteInternet : www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East WestHighway, Bethesda, MD 20814 (tlphone : 301-504-7923, site inter-net : www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation, TheNational Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30333 (tl[hone : 1-800-232-4636, site internet:www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant lectrique qui traverse tout conducteur gnre des champslectromagntiques (CEM) certains endroits. Le courant de soudage

cre un CEM autour du circuit et du matriel de soudage. Les CEMpeuvent crer des interfrences avec certains implants mdicauxcomme des stimulateurs cardiaques. Des mesures de protection pourles porteurs dimplants mdicaux doivent tre prises: par exemple, desrestrictions daccs pour les passants ou une valuation individuelledes risques pour les soudeurs. Tous les soudeurs doivent appliquer lesprocdures suivantes pour minimiser lexposition aux CEM provenantdu circuit de soudage:

1. Rassembler les cbles en les torsadant ou en les attachant avecdu ruban adhsif ou avec une housse.

2. Ne pas se tenir au milieu des cbles de soudage. Disposer lescbles dun ct et distance de loprateur.

3. Ne pas courber et ne pas entourer les cbles autour de votrecorps.

4. Maintenir la tte et le torse aussi loin que possible du matriel ducircuit de soudage.

5. Connecter la pince sur la pice aussi prs que possible de lasoudure.

6. Ne pas travailler proximit dune source de soudage, nisasseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou ledvidoir.

En ce qui concerne les implants mdicaux :

Les porteurs dimplants doivent dabord consulter leur mdecin avantde sapprocher des oprations de soudage larc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le mdecin approuve, il est recommand de suivre lesprocdures prcdentes.


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SECTION 3 DEFINITIONS

3-1. Symbols And Definitions

A Amperes Single Phase Do Not SwitchUnder Load Input

On Off Output

HzHertz

AlternatingCurrent Electrode Positive Electrode Negative Direct Current

Welding Arc V Volts Work Electrode


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SECTION 4 INSTALLATION

4-1. Specifications

A. AC/DC Models

ModeRated Welding

OutputAmperage

Range

MaximumOpen-Circuit

Voltage

Amperes

Input at RatedLoad Output50 Or 60 Hz,

Single-PhaseWeight

220 V 230 V

AC225 A @ 25 Volts AC,

20% Duty Cycle @ 60 Hz;15% Duty Cycle @ 50 Hz

Low: 30 150High: 40 235 80 VAC

47.52.3*

104 lb(47 kg)

DC150 A @ 25 Volts DC,

20% Duty Cycle @ 60 Hz;15% Duty Cycle @ 50 Hz

30 160 80 VDC

AC 300 A @30 Volts AC,20% Duty Cycle @ 50/60 HzLow: 40 200High: 65 300 80 VAC

705.4*

134 lbs

(61 kg)DC 200 A @ 25 Volts DC,20% Duty Cycle @ 50/60 Hz 30 200 80 VDC

Overall Dimensions

Height: 18-3/4 in. (476 mm); Width: 12-3/4 in. (323 mm); Depth: 17-1/2 in. (445 mm)

*While idling

B. AC Models

Rated Welding Output Amperage Range

Max Open-

CircuitVoltage

Amperes Input atRated Load

Output 50 Or 60

Hz, Single-Phase Weight230 V KW

225 A @ 25 Volts AC, 20% Duty Cycle @ 60Hz;

15% Duty Cycle @ 50 Hz

Low: 30 150AHigh: 40 235A 80 VAC

47.52.3*

7.20.22*

85 lb(39 kg)

Overall Dimensions

Height: 18-3/4 in. (476 mm); Width: 12-3/4 in. (323 mm); Depth: 17-1/2 in. (445 mm)

*While idling


17/40OM-316 Page 13

4-2. Duty Cycle Charts

A. For AC/DC Models

2 Minutes Welding 8 Minutes Resting

086 727 / 099 602-A

Duty Cycle is percentage of 10 minutesthat unit can weld at rated load withoutoverheating.

NOTICE Exceeding duty cycle candamage unit and void warranty.

B. For 300/200A Models*A. For 225/150A Models*

*These models have a 15% duty cycle when used with 50 Hz input power.

2 Minutes Welding 8 Minutes Resting

B. For AC Models

001 836-A

Duty Cycle is percentage of 10 minutesthat unit can weld at rated load without

overheating.NOTICE Exceeding duty cycle candamage unit and void warranty.

For 225A Models*

*These models have a 15% duty cycle when used with 50 Hz input power.


18/40

OM-316 Page 14

4-3. Volt-Ampere Curves

A. For AC/DC Models

193 509 / 193 510 / 193 511 / 193 512

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities.Curves of other settings fall be-tween the curves shown.

A. For 225/150A Models

B. For 300/200A Models

0

10

20

30

40

5060

70

80

90

100

0 100 200 300 400

DC Amperes

DC

Volts

MIN MAX

0

10

20

30

40

5060

70

80

90

100

0 50 100 150 200 250 300 350 400 450

AC Amperes

A=LOW RANGE

B=HIGH RANGE

AA B B

0

1020

30

40

50

60

70

80

0 50 100 150 200 250

DC Amperes

DC

Volts

0

1020

30

40

50

60

70

80

90

0 50 100 150 200 250 300 350

AC Amperes

AC

Volts

AC

Volts

AA B B MIN MAX

A=LOW RANGE

B=HIGH RANGE


19/40OM-316 Page 15

B. For AC Models

193 508

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities.Curves of other settings fall be-tween the curves shown.

For 225A Models

0

10

20

30

40

50

60

70

80

90

0 50 100 150 200 250 300

AC Amperes

AC

Volts

A=LOW RANGE

B=HIGH RANGE

A AB B

4-4. Serial Number And Rating Label Location

The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output.For future reference, write serial number in space provided on back cover of this manual.

4-5. Selecting A Location

804 292-A

1 Hand Cart

Use cart or similar device to moveunit.

2 Line Disconnect DeviceLocate unit near correct inputpower.

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

1

2

18 in.(460 mm)

18 in.(460 mm)

18 in.(460 mm)

18 in.(460 mm)


20/40

OM-316 Page 16

4-6. Installing Electrode Holder And Work Clamp

Ref. 802 251-A / 802 105-D

! Turn Off unit and disconnectinput power before installingelectrode holder or workclamp.

Removing Barrel From Elec-trode Holder

1 Electrode Holder2 Barrel3 Access Hole4 Set Screw

Loosen set screw through accesshole and slide barrel away fromelectrode holder.

Installing Electrode Cable andBarrel onto Electrode Holder

5 Electrode Cable From Unit(Has Bare Conductors onEnd)

6 Terminal Screw

Back out terminal screw from elec-trode holder. Insert electrode cablethrough barrel into end of electrode

holder and tighten terminal screwsecurely.

Move barrel toward electrode hold-er and tighten set screw to securebarrel in place.

Installing Work Cable onto WorkClamp

7 Work Clamp8 Work Cable From Unit (Has

Ring Terminal on End)9 Mounting Bolt

Route work cable through workclamp as shown and install ontomounting bolt using supplied hard-ware.

6 mm

Tools Needed:

14 mm

1

4

2

3

6

5

8

97

PIECE


21/40OM-316 Page 17

4-7. Weld Output Cables For weld output cable replacements or extensions, contact your Factory Authorized Service Agent.

4-8. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

50/60 Hz SinglePhase

Input Voltage (V) 220 230

Input Amperes (A) At Rated Output [70] 47.5[67]

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 [90] 50 [80]

Normal Operating Fuses 3 [110] 70 [100]

Min Input Conductor Size In AWG 4 [8]12[10]

Max Recommended Input Conductor Length In Feet (Meters) [75 (23)] 87 (26)[82 (25)]

Min Grounding Conductor Size In AWG 4 [8] 12 [10]

[ ] Electrical Service Requirements For 300/200 AC/DC And 300 AC Models

Reference: 2008 National Electrical Code (NEC) (including article 630)1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.2 Time-Delay fuses are UL class RK5 . See UL 248.3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amps), and UL class H ( 65 amps and

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.


22/40

OM-316 Page 18

4-9. Connecting Input Power

Ref. 802 246-A

For Models Supplied With Plug

! Disconnect and lockout/tag-out input power before instal-ling receptacle.

! Have only qualified personsmake this installation. Seerating label in Section 4-5,andbe sure to supply correct in-

put power.1 Proper Receptacle(NEMA 6-50R)(User-Supplied)

Receptacle must comply with appli-cable codes.

2 Input And GroundingConductors

See size and length using Section4-8. Conductors must comply withapplicable codes.

3 Over-Current Protection

Select type and size of over-currentprotection using Section 4-8.

4 Plug (NEMA 6-50P)

Connect plug to properly installedreceptacle.

Close and secure door on discon-nect device. Remove lockout/tagoutdevice, and place switch in the Onposition.

L1

3

L2

For Models Not Supplied With Plug

! Installation must meet all National andLocal Codes have only qualified per-

sons make this installation.! Disconnect and lockout/tagout input

power before connecting input con-ductors from unit.

! Always connect green or green/yellowconductor to supply grounding termi-nal first, and never to a line terminal.

1 Line Disconnect Device (Switch ShownIn Off Position)

2 Disconnect Device Grounding Terminal3 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow groundingconductor to disconnect device grounding ter-

minal first.4 Disconnect Device Line Terminals5 Black And White Input Conductors L1

And L2

Connect input conductors L1 and L2 to dis-connect device line terminals.

6 Over-Current Protection

Select type and size of over-current protectionusing Section 4-8(fused disconnect switchshown).

Close and secure door on disconnect device.Remove lockout/tagout device, and placeswitch in the On position.

Or

=GND/PE Earth Ground

1

1

2

4

5

6

1

=GND/PE Earth Ground

4

1

3

2


23/40OM-316 Page 19

SECTION 5 OPERATION

5-1. Controls

A. Controls For AC/DC Models

Ref. 217 857-B / 802 105-D

1 Amperage Adjustment Control

2 Power Switch3 Mode Switch

For DC Weld Output

Use mode switch to select polarityof dc output, Electrode Posi-tive/DCEP (+),or Electrode Nega-tive/DCEN ().

For AC Weld Output

Use mode switch to select ac lowrange or high range output.

3 2

1


24/40

OM-316 Page 20

B. Controls For AC Models

Ref. 218 237-A / 802 105-D

1 Amperage Adjustment Control2 Power Switch3 Mode Switch

Use mode switch to select AC lowrange or high range output.

1

3

2


25/40OM-316 Page 21

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

! Disconnect powerbefore maintaining.

Maintain more oftenduring severe conditions.

= Check = Change = Clean = Replace

* To be done by Factory Authorized Service Agent

Reference

Every3Months

Unreadable Labels Weld Terminals Weld Cables

Every6Months

OR

Inside Unit

6-2. Lubricating Shunt Block And Anti-Noise Adjustment

802 248-D

! Turn Off welding powersource and disconnect inputpower.

1 Wrapper

Remove wrapper.

2 Shunt Block

Do not grease screw threadson shunt block.

Apply light coating of high-tempera-ture grease to shaded areas of bothshunt blocks. Turn amperage con-trol handle to spread grease evenly.

3 Noise Adjustment ScrewsIf shunt block vibrates andbecomes noisy, tighten adjustmentscrews 1/4 turn. Install wrapper,turn On unit, and check for shuntnoise. Repeat procedure until noisestops. Do not overtighten. Call yournearest Factory Authorized Ser-vice Agent if noise continues.

! Install wrapper beforeturning On power.

5/16, 3/8 in.

2

3

2

Tools Needed:

1/2 in.

1


26/40

OM-316 Page 22

6-3. Reinstalling Amperage Adjustment Indicator

804 293-A / Ref. 802 248-D / Ref. 218 237-A

! Turn Off welding powersource and disconnect inputpower.

1 Wrapper

Remove wrapper from unit.

2 Crank Handle3 Shunt Shaft4 Transformer And Shunt

(Located Inside Unit)Insert crank handle onto shuntshaft protruding through front paneland turn crank handle to adjustshunt to the proper vale of X, de-pending on model (see detail oftransformer and shunt.

Remove crank handle.

5 Pinion Gear

Install pinion gear onto front panelmaking sure anti-rotation pins are inholes on front panel.

6 Pointer Gear

Install pointer gear overtop of piniongear and rotate so pointer is indicat-ing 130 Amps on AC Low Rangescale (see example).

Install crank handle overtop the sta-tor/pinion gear assembly with thehandle straight down. It may benecessary to turn the handle slight-ly so vertical alignment is possible.

7 Securing Screw

Install securing screw through han-dle, into threaded hole in shuntshaft. Tighten securely.

Reinstall wrapper.

5/16, 3/8 in.

4

3

1

Tools Needed:

X

For 225 A models, X = 21/2 in.For 300 A models, X = 23/8 in.

Viewed from right side of unit.

Proper alignment of pointer and crank handle.T-20 Torx

3

2

56

7


27/40OM-316 Page 23

6-4. Troubleshooting

Trouble Remedy

No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 4-9).

Check and replace line fuses if open. Reset breakers if necessary (see Section 4-9).

Fan does not run; weld output okay. Be sure nothing is blocking movement of fan. If fan does not run freely, replace fan motor.

Erratic weld current. Clean and tighten all weld cable connections.

Erratic arc with excessive spatter. Use dry, properly stored electrodes.

Shorten arc length.

Reduce amperage setting (see Section 5-1).

Electrode freezing to work. Increase amperage setting (see Section 5-1).

Increase arc length.

Use dry, properly stored electrodes.

Noise and vibration from shunt block. Lubricate shunt block and/or tighten adjustment screws (see Section 6-2).


28/40

OM-316 Page 24

SECTION 7 ELECTRICAL DIAGRAMS

191 364

Figure 7-1. Circuit Diagram For 225/150 AC/DC (230 Volts) Models

191 368

220

PRI

SEC

T1

GRN

VOLTONLY

S2

WORK ELECTRODE

R Z1

SR1

S.O.P.

POWERCORD

FM

S1

S.O.P.

Figure 7-2. Circuit Diagram For 300/200 AC/DC (220 Volts) Models


29/40

OM-316 Page 25

191 362

WORK

230

PRI

SEC

T1

GRN

VOLTONLY

S2AC HIGH

AC LOW

ELECTRODE

PLG1

FM

S1

Figure 7-3. Circuit Diagram For 225 AC (230 Volts) Models


30/40

OM-316 Page 26

SECTION 8 STICK WELDING (SMAW) GUIDELINES

8-1. Stick Welding Procedure

stick 201002 151 593

! Weld current starts whenelectrode touches work-piece.

! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clampas close to the weld aspossible.

Always wear appropriate per-sonal protective clothing.

1 Workpiece

Make sure workpiece is clean be-fore welding.

2 Work Clamp3 Electrode

A small diameter electrode re-quires less current than a largeone. Follow electrode manufactur-ers instructions when setting weldamperage (see Section 8-2).

4 Insulated Electrode Holder5 Electrode Holder Position6 Arc Length

Arc length is the distance from theelectrode to the workpiece. A shortarc with correct amperage will givea sharp, crackling sound.7 Slag

Use a chipping hammer and wirebrush to remove slag. Removeslag and check weld bead beforemaking another weld pass.

1

4

3

5

2

7

6

Tools Needed: Equipment Needed:

Constant CurrentWelding Power Source


31/40

OM-316 Page 27

8-2. Electrode and Amperage Selection Chart

Ref. S-087 985-A

3/321/8

5/323/167/321/4

1/165/643/321/8

5/323/167/321/4

3/321/8

5/323/167/321/4

3/32

1/85/323/167/321/4

3/321/8

5/323/167/321/4

3/321/8

5/323/163/321/8

5/32

6010&

6011

6013

7014

7018

7024

Ni-Cl

308L

50 100

150

200

250

300

350

400

450

E

LECTRODE

DC*

AC

POSITION

PENETRATION

USAGE

MIN. PREP, ROUGHHIGH SPATTER

GENERAL

SMOOTH, EASY,FAST

LOW HYDROGEN,STRONG

SMOOTH, EASY,FASTER

CAST IRONSTAINLESS

DEEP

DEEPLOW

MED

LOW

LOWLOW

ALL

ALLALL

ALL

ALL

FLATHORIZFILLETALLALL

EP

EPEP,EN

EP,EN

EP

EP,EN

EPEP

6010

60116013

7014

7018

7024

NI-CL308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

ELECTRODE

AMPERAGE

RANGE

DIAMETER

MED

8-3. Striking an Arc

S-0049 / S-0050

1 Electrode2 Workpiece3 Arc

Scratch Technique

Drag electrode across workpiecelike striking a match; lift electrodeslightly after touching work. If arcgoes out, electrode was lifted toohigh. If electrode sticks to work-piece, use a quick twist to free it.

Tapping Technique

Bring electrode straight down toworkpiece; then lift slightly to startarc. If arc goes out, electrode waslifted too high. If electrode sticks toworkpiece, use a quick twist to freeit.

1

2

3

1

3

2


32/40

OM-316 Page 28

8-4. Positioning Electrode Holder

S-0060

90 90

10-30

45

45 10-30

1 End View Of Work Angle2 Side View Of Electrode Angle

1

1

2

2

Groove Welds

Fillet Welds

8-5. Poor Weld Bead Characteristics

S-0053-A

1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater During Welding

4 Bad Overlap5 Poor Penetration

5

4

2 3

1

8-6. Good Weld Bead Characteristics

S-0052-B

1 Fine Spatter2 Uniform Bead3 Moderate Crater During

Welding

Weld a new bead or layer for each1/8 in. (3.2 mm) thickness in met-als being welded.

4 No Overlap5 Good Penetration into Base

Metal

1

52 3 4


33/40

OM-316 Page 29

8-7. Conditions That Affect Weld Bead Shape

S-0061

Slow Normal Fast

10- 30

Drag

Too Short Normal Too Long

Spatter

Angle Too Small Angle Too LargeCorrect Angle

Electrode Angle

Arc Length

Travel Speed

Weld bead shape is affectedby electrode angle, arclength, travel speed, and thick-ness of base metal.

8-8. Electrode Movement During Welding

S-0054-A

Normally, a single stringerbead is satisfactory for mostnarrow groove weld joints;however, for wide groove weldjoints or bridging across gaps,a weave bead or multiplestringer beads work better.

1 Stringer Bead SteadyMovement Along Seam

2 Weave Bead

Side to SideMovement Along Seam3 Weave Patterns

Use weave patterns to cover awide area in one pass of the elec-trode. Do not let weave width ex-ceed 2-1/2 times diameter ofelectrode.

1 2

3


34/40

OM-316 Page 30

8-9. Groove (Butt) Joints

S-0062

1 Tack Welds

Prevent edges of joint from draw-ing together ahead of electrode bytack welding the materials in posi-tion before final weld.

2 Square Groove Weld

Good for materials up to 3/16 in. (5mm) thick.

3 Single V-Groove Weld

Good for materials 3/16 3/4 in.(5-19 mm) thick. Cut bevel withoxyacetylene or plasma cuttingequipment. Remove scale frommaterial after cutting. A grinder canalso be used to prepare bevels.

Create 30 degree angle of bevel onmaterials in V-groove welding.

4 Double V-Groove Weld

Good for materials thicker than3/16 in. (5 mm).

30

2

1

1/16 in.(1.6 mm)

3 4

8-10. Lap Joint

S-0063 / S-0064

1 Electrode2 Single-Layer Fillet Weld

Move electrode in circular motion.

3 Multi-Layer Fillet Weld

Weld a second layer when a heavi-er fillet is needed. Remove slag be-fore making another weld pass.Weld both sides of joint for maxi-mum strength.

30Or Less

30Or Less

1 1

2 3

8-11. Tee Joint

S-0060 / S-0058-A / S-0061

1 Electrode2 Fillet Weld

Keep arc short and move at defi-nite rate of speed. Hold electrodeas shown to provide fusion into thecorner. Square edge of the weldsurface.For maximum strength weld bothsides of upright section.

3 Multi-Layer Deposits

Weld a second layer when a heavi-er fillet is needed. Use any of theweaving patterns shown in Section8-8. Remove slag before makinganother weld pass.

45Or

Less

1

2

1

32


35/40

OM-316 Page 31

8-12. Weld Test

S-0057-B

1 Vise2 Weld Joint3 Hammer

Strike weld joint in direction shown.A good weld bends over but doesnot break.

2 To 3 in.

1/4 in.

3

21

2 To 3 in.

3

2

1

(51-76 mm)

(6.4 mm)

(51-76 mm)

8-13. Troubleshooting

Porositysmall cavities or holes resulting from gas pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface beforewelding.

Excessive Spatterscattering of molten metal particles that cool to solid form near weld bead.


Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

Incomplete Fusionfailure of weld metal to fuse completely with base metal or a preceedingweld bead.


Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface beforewelding.


36/40

OM-316 Page 32

Lack of Penetration Good Penetration

Lack Of Penetrationshallow fusion between weld metal and base metal.


Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

Good PenetrationExcessive Penetration

Excessive Penetrationweld metal melting through base metal and hanging underneath weld.


Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Burn-Throughweld metal melting completely through base metal resulting in holes where nometal remains.


Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Waviness Of Beadweld metal that is not parallel and does not cover joint formed by base metal.


Unsteady hand. Use two hands. Practice technique.

Base metal movesin the direction of

the weld bead.

Distortioncontraction of weld metal during welding that forces base metal to move.


Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.


37/40

OM-316 Page 33

SECTION 9 PARTS LIST

802 245-F

Hardware is common andnot available unless listed.

27

7

6

8

5

4

11

10

23

3

1418

25

24

22

22

21

2019

18 17

16

15

13

12

92

1

26

Figure 9-1. Main Assembly (AC/DC model illustrated)


38/40

OM-316 Page 34

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-1. Main Assembly

Quantity

1 224 794 LABEL, warning general precautionary (electrode) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 217 732 LABEL, warning general precautionary (EN/FR) vert 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 +210 309 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 S2 190 079 SWITCH, secondary 2-position (AC 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 S2 225 647 SWITCH, secondary 4-position w/jumpers (all AC/DC models) 1. . . . . . . . . . . . . . . . . . . . . . .4 T1 190 170 TRANSFORMER & SHUNT, (230V 225A model) (including) 1. . . . . . . . . . . . . . . . . . . . . . . . .4 T1 192 179 TRANSFORMER & SHUNT, (220V, AC/DC 300A model) (including) 1. . . . . . . . . . . . . . . . .5 190 242 SCREW, lead shunt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 190 150 SHUNT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 147 907 SCREW, 5/16-18 x 1.75 w/loctite 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 080 522 BLOCK, anti-noise shunt 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Z1 190 145 STABILIZER, (AC/DC 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Z1 192 177 STABILIZER, (AC/DC 300A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 SR1 190 303 RECTIFIER, (AC/DC 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 SR1 190 965 RECTIFIER, (AC/DC 300A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 S1 124 511 SWITCH, (all 225A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 S1 045 834 SWITCH, (all 300A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 +225 857 CASE SECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 PLG1 088 297 CORD SET (all 225A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 204 141 CABLE (all 300A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 111 443 BUSHING, strain relief (all 225A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 604 102 CONNECTOR (all 300A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 185 759 LABEL, warning electric shock & input power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 217 733 LABEL, warning electric shock & input power (EN/FR) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 FM 190 234 MOTOR, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 005 656 BLADE, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 LABEL, control/output (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 190 296 GEAR, pinion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 190 295 GEAR, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 190 241 HANDLE, control current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 190 538 LEAD LIST 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 215 248 KIT, electrode holder & gnd clamp w/hardware 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 LABEL, brand identity (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 207 074 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 111 644 BUSHING, strain relief .370/.430 ID X .875 mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 494 907 SCREW, K50 x 20 pan hd-trx stl pld thread forming 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.


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

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

Effective January 1, 2010(Equipment with a serial number preface of MA or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to itsoriginal retail purchaser that new Miller equipment sold after theeffective date of this limited warranty is free of defects in materialand workmanship at the time it is shipped by Miller. THISWARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replaceany warranted parts or components that fail due to such defects inmaterial or workmanship. Miller must be notified in writing withinthirty (30) days of such defect or failure, at which time Miller willprovide instructions on the warranty claim procedures to befollowed.

Miller shall honor warranty claims on warranted equipment listedbelow in the event of such a failure within the warranty timeperiods. All warranty time periods start on the delivery date of theequipment to the original end-user purchaser, and not to exceedone year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to anInternational distributor.

1. 5 Years Parts 3 Years Labor* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules2. 3 Years Parts an

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