Programmable Precision DC TIG Intellitig 4 · 2019-11-13 · Intellitig 4 Processes Description TIG...

Intellitig 4

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

Programmable Precision DC TIGController

OM-2803C 144 084C

January 1999

With An Inverter Power Source:

Visit our website at

www.MillerWelds.com

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

Thank you and congratulations on choosing Miller. Nowyou can get the job done and get it done right. We knowyou don’t have time to do it any other way.

That’s why when Niels Miller first started building arcwelders in 1929, he made sure his products offeredlong-lasting value and superior quality. Like you, hiscustomers couldn’t afford anything less. Miller productshad to be more than the best they could be. They had tobe the best you could buy.

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

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

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

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

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

From Miller to You

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

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

TABLE OF CONTENTS

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

SECTION 2 – SPECIFICATIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Control Unit 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Typical Process Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Setting DIP Switch SW1 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Installing Gas Supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Connecting Remote Pendant 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Remote 14 Receptacle Information And Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Function Of User Relays 1 And 2 (Use Is Optional) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. User Relay Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Weld Input And Output Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Connecting Input Power 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Safety Equipment 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Work Clamp 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Digital Display 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Program/Run/Reset Keyed Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Mode Selector Switch 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Parameter Select Push Button 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Right/Increase Push Button 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Left/Decrease Push Button 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Purge Push Button 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Gas Control And Flow Rate Meter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Power Switch 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13. Remote Pendant 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14. Shielding Gas 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Overload Protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Adjusting Spark Gaps 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – INTRODUCTION TO PROGRAMMING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Introduction 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Modes Of Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PROGRAMMING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. General 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Automatic Mode 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Semi-Automatic Mode 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Manual GTAW Mode 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. SMAW Mode 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Editing A Program 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Dry Run Feature 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. Stop Watch Feature 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9. Linking Programs 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10. Combining Programs 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – SEQUENCE OF OPERATION 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Gas Tungsten Arc Welding (GTAW) In The Automatic Mode 43. . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Gas Tungsten Arc Welding (GTAW) In The Semi-Automatic Modes 43. . . . . . . . . . . . . . . . . . . 8-3. Gas Tungsten Arc Welding (GTAW) In The Manual Mode 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Shielded Metal Arc Welding (SMAW) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Executing Linked Programs 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Executing Combined Programs 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Shutting Down 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – DIAGNOSTICS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Introduction 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Diagnostics Program 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – ELECTRICAL DIAGRAMS 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 – HIGH FREQUENCY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 – TUNGSTEN ELECTRODE 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Selecting Tungsten Electrode 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2. Preparing Tungsten 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 – PARTS LIST 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY

OM-2803 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_5/97

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, 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 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 itsOwner’s Manual and national, state, and local codes.

� Always verify the supply ground – check and be sure that inputpower cord ground wire is properly connected to ground 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 use work clamp or work cable.

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

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

� Wear a safety harness if working above floor level.

� Keep all panels and covers securely in place.

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

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

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

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

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

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

FUMES AND GASES can be hazardous.

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

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

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

� Read the Material Safety Data Sheets (MSDSs) and themanufacturer’s 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.

OM-2803 Page 2

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

ARC RAYS can burn eyes and skin.

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

� Wear approved safety glasses with side shields under yourhelmet.

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

� Wear protective clothing made from durable, flame-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 atcontact tip when not in use.

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

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

FLYING METAL can injure eyes.

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

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

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch.

MAGNETIC FIELDS can affect pacemakers.

� Pacemaker wearers keep away.� Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

� Wear approved ear protection if noise level ishigh.

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

CYLINDERS can explode if damaged.

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

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

� Keep cylinders away from any welding or other electrical circuits.

� Never drape a welding torch over a gas cylinder.

� Never allow a welding electrode to touch any cylinder.

� Never weld on a pressurized cylinder – explosion will result.

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

� Turn face away from valve outlet when opening cylinder valve.

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

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

OM-2803 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 before

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

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

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

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

� Do not press gun trigger until instructed to doso.

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

MOVING PARTS can cause injury.

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

closed and securely in place.

H.F. RADIATION can cause interference.

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

� Have only qualified persons familiar withelectronic equipment perform this installation.

� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

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

� Have the installation regularly checked and maintained.

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

ARC WELDING can cause interference.

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

� Be sure all equipment in the welding area iselectromagnetically compatible.

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

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

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

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

1-4. Principal Safety Standards

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

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

OM-2803 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: “The body of evidence, in thecommittee’s 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.

OM-2803 Page 5

SECTION 2 – SPECIFICATIONS

2-1. Control Unit

Specification Description

Welding Processes Gas Tungsten Arc (GTAW), Shielded Metal Arc (SMAW) Welding

Welding Circuit Rating 250 Amperes At 100% Duty Cycle

Type Of Input Power When Used With 115 Volts: 115 Volts AC Single-Phase 50/60 Hz, 1.0 AmperesWhen Used With 230 Volts: 230 Volts AC Single-Phase 50/60 Hz, 0.5 Amperes

Overall Dimensions Height: 9-1/8 in (232 mm); Width: 9-1/2 in (241 mm); Length: 19-1/4 in (489 mm)

Weight Net: 30 lb (13.6 kg); Ship: 37 lb (16.8 kg)

OM-2803 Page 6

SECTION 3 – INSTALLATION

WARNINGHIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,computers, and communications equipment.• Have only qualified person familiar with electronic equipment perform this installation.

• Read and follow entire Section 11 for proper location and installation requirements for high-frequency equipment before installingunit. swarn13.1 4/93

3-1. Typical Process Connections

ST-800 505 / ST-800 504

1 Welding Power Source

2 Gas Cylinder3 Control Unit

4 Remote Pendant Control

5 Torch6 Work Clamp

7 Foot Control

8 Electrode Holder

For GTAW Welding

For SMAW Welding

1

3

4

5

6 7

8

2

3

6 7

1

OM-2803 Page 7

3-2. Setting DIP Switch SW1

WARNINGELECTRIC SHOCK can kill• Do not touch live electrical parts.

• Turn Off welding power source and control unit, anddisconnect input power before setting DIP switches.

STATIC ELECTRICITY can damageparts on circuit boards.• Put on grounded wrist strap BEFORE handling

boards or parts.

fwarn2.1* 9/91 / fwarn5.1* 9/91

ST-146 842 / ST-800 506

Set DIP switch positions as follows:

1 Front Panel

2 Retaining Screw

Loosen retaining screw, and openhinged front panel.

3 Microprocessor Board PC1

4 DIP Switch SW1

Factory default settings shown. Toset a position, depress the end nearthe desired choice.

5 Positions 1 And 2

In Automatic and Semi-Automatic1, weld amperage can be adjustedup or down during weld using re-mote pendant. Define amperageadjustment range limits by settingpositions 1 and 2 according to table.

6 Position 3

Use position 3 to select whetherpulses are defined as time or fre-quency values.

Set Off to define as frequency.

Set On to define as time.

7 Position 4

Set Off to run diagnostics program.Set On to stop diagnostics pro-gram, and for all other operations.

8 Positions 7 And 8

Set 7 and 8 according to table to se-lect Semi-Automatic Modes 1 thru5.

Close front panel and tighten retain-ing screw after setting SW1.

12

34

56

78

Position

On

On

Off

Off

On

Off

On

Off

±5 Amperes

±10 Amperes

±20 Amperes

±40 Amperes

On

On

Off

Off

On

Off

On

Off

1Position

2Position

7Position

8

DefinedAmperage

AdjustmentLimit

DefinedSemi-Automatic

Mode

*1

2

3

4

*5On On

*Semi-Automatic 1 mode is defined whenremote Stop switch is connected. Semi-Automatic 5 mode is defined when remote Stopswitch is not connected.

Off

5

8

6

= On

4

7

Positions 5 and 6 are not used.

Tools Needed:

1

2

3

OM-2803 Page 8

3-3. Installing Gas Supply

WARNINGCYLINDERS can explode if damaged.• Keep cylinders away from welding and other

electrical circuits.• Never touch cylinder with welding electrode.

• Always secure cylinder to running gear, wall, orother stationary support.

BUILDUP OF SHIELDING GAS can harmhealth or kill.• Shut off shielding gas supply when not in use.

warn4.1 9/91

Allowable pressure range for shielding gas input is 30-50 psi (207 to 345 kPa).NOTE

Obtain gas cylinder and chain torunning gear, wall, or other station-ary support so cylinder cannot falland break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Gas Hose Connection

Fitting has 5/8-18 right-handthreads. Obtain and install gashose.

6 Flow Adjust

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

7 Gas In Fitting

8 Gas Out Fitting

The Gas In and Gas Out fittingshave 5/8-18 right-hand threads.Obtain proper size, type, and lengthhose and make connections as fol-lows:

Connect hose from shielding gassupply regulator/flowmeter to GasIn fitting.

Connect shielding gas hose fromtorch to Gas Out fitting.

ssb3.3* 6/93 – ST-146 841-A / Ref. ST-158 697-A / Ref. ST-140 732

Tools Needed:

1

2

3

45

6

Argon Gas

5/8, 1-1/8 in

7

8

To Torch

OM-2803 Page 9

3-4. Connecting Remote Pendant

1 Remote Pendant

2 Remote 4 Receptacle RC2

3 Keyway

4 Plug

5 Threaded Collar

Use receptacle to connect suppliedremote pendant. User-wired con-trols equivalent to remote controlare also connected to thisreceptacle.

To connect to this receptacle, alignkeyway, insert plug, and tightenthreaded collar.

Socket Information:

A Normally closed contact with socket C openswhen pendant Stop button is pressed.

B Normally open contact with socket C closes whenpendant Decrease button is pressed.

C +24 volts dc.

D Normally open contact with socket C closes whenpendant Start/Increase button is pressed.

sb7.1* 8/92 – ST-146 841-A / Ref. ST-140 732 / ST-146 839 / Ref. S-0446-A

DA

CB

1

45

23

REMOTE 4

3-5. Remote 14 Receptacle Information And Connections

Socket Information:

Remote Contactor

A +24 volts dc.

B Contact closure to pin A completes +24 volts dccontactor control circuit.

Remote Amperage/Voltage Control

C Command reference; +10 volts dc.

D Control circuit common.

E Input command signal (potentiometer wiper or 0 to+10 volts dc).

The remaining sockets are not used.

sb7.1* 8/92 – ST-146 841-A / Ref. ST-140 732 / Ref. S-0004-A / S-0750

1 Remote 14 Receptacle RC3

2 Keyway

3 Plug

4 Threaded Collar

To connect to this receptacle, alignkeyway, insert plug, and tightenthreaded collar.

34

A JB

K I

C L N H

D M GE F

1 2REMOTE 14

OM-2803 Page 10

3-6. Function Of User Relays 1 And 2 (Use Is Optional)

Ref. SB-139 983

User relays 1 and 2 can be used tocontrol external devices, such asfixtures.

When enabled, relay 1 changesstates according to programmedtime delay values in the Automatic,Semi-Automatic 1, and Semi-Auto-matic 5 modes. In the remainingmodes, relay 1 is not functional.The relay is also not functional ifdisabled.

1 Start Delay Range

The programmed start delay valuedetermines how long after the Start/Increase push button is presseduser relay 1 will energize. Therange of acceptable values is 0.0 to120.0 seconds. In order to functionproperly, the start delay value mustnot delay energization beyond theend of weld/peak current.

2 Stop Delay Range

The programmed stop delay valuedetermines how long after weld/peak current ends user relay 1 willdeenergize. The range is 0.0 to120.0 seconds.

The stop delay time cannot delaydeenergization of user relay 1beyond the end of postflow.

InitialCurrent

Weld/PeakCurrentInitial

SlopeFinalSlope

FinalCurrent

Preflow Postflow

1

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

2

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

12

1 Relay 2 Energizes

2 Relay 2 Deenergizes

Relay 2 energizes when initial cur-rent starts if an arc is detected, anddeenergizes when final currentends. If an arc is not detected, relay2 does not energize.

In Automatic mode and Semi-Auto-matic modes 1 and 5, relay 2changes state only if the relay is en-abled during programming. In Se-mi-Automatic modes 2, 3, and 4,relay 2 changes state whether en-abled or not.

User Relay 1

User Relay 2

OM-2803 Page 11

3-7. User Relay Connections

WARNINGELECTRIC SHOCK can kill• Do not touch live electrical parts.

• Turn Off welding power source and control unit, anddisconnect input power before making user relayconnections.


boards or parts.

fwarn2.1* 9/91 / fwarn5.1* 9/91

ST-146 841-A / ST-800 506 / Ref. SB-139 983

When making connections to userrelay contacts, use #28 to #18AWG solid or stranded insulatedwire. Do not strip insulation fromend of wire before making connec-tions. The contacts are rated at 5amperes, 230 volts each.

Open front panel and remove topfrom unit.

1 Strain Relief Connector

Loosen strain relief and insertwires. Route wires to desired termi-nals (see table).

2 Interface Board PC3

3 Terminal Assembly (Six Total)

4 Lever Up

5 Wire Insertion Hole

6 Lever Down

For each connection, lift terminal le-ver, insert wire, and push terminallever down to locked position.

Tighten strain relief when all con-nections are made. Reinstall top,and close front panel.

Connect leads to external devices.To avoid high frequency interfer-ence, route leads away from weldcables.

3

Connection OnTerminal Strip

1

2

3

4

5

6

Function

User Relay #2 N.O. Contact

User Relay #2 Common

User Relay #2 N.C. Contact

User Relay #1 N.O. Contact

User Relay #1 Common

User Relay #1 N.C. Contact

N.O. = normally openN.C. = normally closed

4

5

6

1

2

OM-2803 Page 12

3-8. Weld Input And Output Connections

WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.

• Turn Off control unit and welding power source, and disconnect input power before making connections.

swarn12.1* 2/92

1 Positive Input Plug

Connect weld cable from positive(+) terminal on welding powersource to Positive Input plug.

2 Negative Input Plug

Connect weld cable from negative(–) terminal on welding powersource to Negative Input plug.

GTAW DC Electrode Negative/Straight Polarity (DCEN)

3 Torch Receptacle

Connect torch cable.

4 Positive (+) Receptacle

Connect one end of work cable,connect remaining end to work-piece.

For DC Electrode Positive (DCEP),reverse cable connections.

SMAW DC Electrode Positive/Reverse Polarity (DCEP)

4 Positive (+) Receptacle

Connect electrode holder cable.

5 Negative (–) Receptacle

Connect one end of work cable,connect remaining end to work-piece.

For DC Electrode Negative(DCEN), reverse cable connec-tions.

ssb2.2 11/92 – Ref. S-0752 / ST-146 841-A

Tools Needed:

3/4 in

Input Plug Connections

Output Receptacle Connections For GTAW Welding

Output Receptacle Connections For SMAW Welding

Positive (+)

Negative (–)

1

2

Positive (+) Negative (–)

Torch

45

Positive (+) Negative (–)

Torch

4

3

OM-2803 Page 13

3-9. Connecting Input Power

WARNINGELECTRIC SHOCK can kill.• Do not touch live electrical parts.

• Turn Off control unit and welding power source, and disconnect input power before inspecting or installing.

• Have only qualified persons install unit.

• Installation must meet National Electrical Code and all other codes.swarn3.1* 2/93

A. To Power Source Receptacle Information And Connections

Socket Information:

A Provides connection to program-controlled relay contact internalto control unit; contact makes connection with relay contact con-nected to pin B to energize welding power source.

B Contact closure to pin A completes contactor control circuit.

D Control circuit common with respect to pin E.

E Provides 0 to +10 volt dc command signal with respect to pin D.

G 115 volts ac circuit common; also connected to welding powersource chassis.

I Up to 1.0 amperes of 115 volts ac, 60 Hz, with respect to socketG (circuit common).

K Machine chassis (circuit common).

The remaining sockets are not used.

sb7.1* 8/92 – ST-146 841-A / Ref. S-0004-A / S-0750

1 To Power Source ReceptacleRC1

2 Keyway

3 Plug

4 Threaded Collar

Connections to this receptacle re-quire an interconnecting cord that issuitable for the welding powersource being used with the controlunit.

To connect to this receptacle, alignkeyway, insert plug, and tightenthreaded collar. See Section 3-9Bfor instructions on connecting theremaining end of the interconnect-ing cord to the welding powersource.

34

1 2

AJ

BKI

CLNH

DMG

EF

OM-2803 Page 14

B. Interconnecting Cord Connections

ST-800 288

Depending on welding powersource used, select and obtaininterconnecting cord and makeconnections as follows:

1 Interconnecting Cord With14-Pin Plug Only

Connect to Remote 14 receptacleon welding power source. Align key-way, insert plug, and tightenthreaded collar.

2 Interconnecting Cord With14-Pin Plug And 115 Volt ACPlug

Connect 14-pin plug to Remote 14receptacle on welding powersource. Align keyway, insert plug,and tighten threaded collar.

Insert 115 volt ac plug into 115 voltac duplex receptacle.

3 Interconnecting Cord With5-Pin Plug And 115 Volt ACPlug

Connect 5-pin plug to Remote 5 re-ceptacle on welding power source.Align keyway, insert plug, and tight-en threaded collar.

Insert 115 volt ac plug into 115 voltac duplex receptacle.

1

2

3

C. Changing Jumper Links For 230 Volts Operation

ST-800 506

For applications requiring 230 voltsinput power, proceed as follows:

Open front panel, and remove topcover.

Route suitable customer-suppliedinput power cable thru strain reliefon rear panel. Disconnect existingleads 1 and 2 (circuit common) fromPower switch S1, and connect newcable leads to same S1 terminals.

Change jumper links positions asfollows:

1 Input Voltage Label

2 Input Terminal Board TE1

3 Input Voltage Jumper Links

Move links as shown on label.

Reinstall top cover, and close frontpanel.

1

1/4 in

Tools Needed:

2

3

230 VOLTS

S-072 212-A

115 VOLTS

OM-2803 Page 15

SECTION 4 – OPERATION

WARNINGELECTRIC SHOCK can kill.• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Do not touch live electrical parts.

• Keep all panels and covers securely in place.

FUMES AND GASES can be hazardousto your health.• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) andmanufacturer’s instructions for material used.

WELDING can cause fire or explosion.• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;NOISE can damage hearing.• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

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

• Keep all doors, panels, covers, and guards closedand securely in place.

MAGNETIC FIELDS FROM HIGH CUR-RENTS can affect pacemaker operation.• Pacemaker wearers keep away.

• Wearers should consult their doctor before goingnear arc welding, gouging, or spot welding opera-tions.

See Safety Precautions at beginning of manual for ba-sic welding safety information. swarn6.1 10/91

4-1. Controls

1 Power Switch (On RearPanel)

2 Digital Display

3 Right/Increase Push Button

4 Parameter Select Push Button

5 Mode Switch

6 Program/Run/Reset KeyedSwitch

7 Left/Decrease Push Button

8 Purge Push Button

9 Gas Control

10 Gas Flow Rate Meter

11 Remote Pendant

ST-800 503 / Ref. ST-146 839

11

1 2

3

4

5

6

10

9

8

7

4-2. Safety Equipment

1 Insulating Gloves

2 Safety Glasses With SideShields

3 Welding Helmet

Wear dry insulating gloves, safetyglasses with side shields, and awelding helmet with a correct shadeof filter (see ANSI Z49.1).

sb3.1 10/91

1 2 3

OM-2803 Page 16

4-3. Work Clamp

1 Work Clamp

Connect work clamp to a clean,paint-free location on workpiece, asclose to weld area as possible.

Use wire brush or sandpaper toclean metal at weld joint area. Usechipping hammer to remove slagafter welding.

sb4.1 2/93

Tools Needed:1

4-4. Digital Display

1 Digital Display

Depending on the mode and pro-grammed options, the digital dis-play either shows the steps in thewelding program or weld output.

Program Displays

Use display to enter and read val-ues. If weld program steps areshown during operation, the pro-grammed time values decrease asprocess time runs out.

Weld Output Metering

If selected during programming, thedigital display shows weld outputamperage and voltage values asthe weld program is carried out.Weld output metering is always ac-tive when a Manual GTAW orSMAW program is carried out.

If the voltage value exceeds 99.9volts, the display shows OVR.

1

Ref. ST-139 983

4-5. Program/Run/Reset Keyed Switch

1 Program/Run/Reset KeyedSwitch

Use switch for selecting these threefunctions:

Program

Use to enter, change, and/or ex-ecute a program.

Run

Use to execute a program only. Keycan be removed to prevent unau-thorized access to program.

Reset

Use before switching between Run/Program positions when unit is On.

For example, use Program positionto enter program, move to Resetmomentarily, and move to Run toexecute program. Remove key ifdesired. If changing program, moveto Reset momentarily before mov-ing back to Program.

1

OM-2803 Page 17

4-6. Mode Selector Switch

1 Mode Selector Switch

Use switch to select weld mode.

1

4-7. Parameter Select Push Button

1 Parameter Select Push Button

Use switch for these functions:

When display contains multiple pa-rameters, pressing switch selectseach parameter in sequence.When a parameter is selected, itflashes and is ready to have a valueentered. Pressing switch while thelast parameter in a display is se-lected deselects that parameterwithout selecting the nextparameter.

Pressing switch when a displayshows an either/or option togglesthe displayed option between thetwo choices.

1

4-8. Right/Increase Push Button

1 Right/Increase Push Button


Pressing switch while a parameteris selected increases that parame-ter value. Press and hold switch torapidly increase the value.

Pressing switch without a parame-ter being selected scrolls to nextdisplay in the sequence.

1

To zero a parameter value, select pa-rameter and press Right/Increaseand Left/Decrease switches at thesame time.

OM-2803 Page 18

4-9. Left/Decrease Push Button

1 Left/Decrease Push Button


Pressing switch while a parameteris selected decreases that parame-ter value. Press and hold switch torapidly decrease the value.

Pressing switch without a parame-ter being selected scrolls toprevious display in the sequence.

1

To zero a parameter value, select pa-rameter and press Right/Increaseand Left/Decrease switches at thesame time.

4-10. Purge Push Button

1 Purge Push Button

Use switch to momentarily ener-gize gas valve and purge air fromtorch shielding gas line, and to allowshielding gas regulator and flowrate meter to be adjusted withoutenergizing the welding circuit.

Switch is only active when therepeating displays are shown.

1

4-11. Gas Control And Flow Rate Meter

1 Gas Control

Use control to adjust flow of shield-ing gas.

2 Shielding Gas Flow RateMeter

Meter indicates flow rate of shield-ing gas. Meter shows cubic feet perhour and has a range of 0-60 feetper hour with Argon shielding gas.

2

1

OM-2803 Page 19

4-12. Power Switch

1 Power Switch

Use switch to turn power to controlunit On and Off.

ST-146 841-A / Ref. ST-140 732

1

4-13. Remote Pendant

1 Remote Pendant

Use for remote operation in theAutomatic and Semi-Automaticmodes only. Connect to Remote 4receptacle (see Section 3-4).

2 Stop Push Button

3 Start/Increase Push Button

4 Decrease Push Button

Push button functions are de-scribed in operating instructions forAutomatic and Semi-Automaticmodes.

Ref. ST-146 839

1

2

3

4

4-14. Shielding Gas

WARNINGBUILDUP OF SHIELDING GAS can harm health or kill.• Shut off shielding gas supply when not in use.

warn1.1 9/91

1 Shielding Gas Cylinder

2 Valve

3 Torch Switch

4 Foot Control

Open valve on cylinder just beforewelding.

Torch trigger or foot control turnsweld output and gas flow on and off.

Close valve on cylinder when fin-ished welding.

sb5.2* 2/92 – S-0621-C / ST-159 059

2

14

OR

3

OM-2803 Page 20

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

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

• Turn Off welding power source and control unit, anddisconnect input power before inspecting,maintaining, or servicing.

HOT PARTS can cause severe burns.• Allow cooling period before maintaining or servicing.



boards or parts.

Maintenance to be performed only by qualified persons.

WARNING

swarn8.1* 2/93

5-1. Routine Maintenance

Turn Off all power before maintaining.3 Months

OR

Blow OutOr

VacuumInside

ReplaceUnreadable

Labels

6 Months

Remote Cords

Gas Hose Torch Cable

ReplaceCracked

Parts

3 Months

Tape OrReplaceCrackedCables

ST-146 842

CleanAnd

Tighten WeldConnections

OM-2803 Page 21

5-2. Overload Protection

READ SAFETY BLOCKS at start ofSection 5 before proceeding.WARNING

ST-800 506 / Ref. ST-146 844-A

Turn Off welding power source andcontrol unit, and disconnect inputpower.

Open front panel, and remove topcover.

1 Fuse F1

F1 protects the control circuitryfrom overload. If F1 opens, the con-trol unit shuts down.

Check fuse and replace if needed.See Parts List for fuse rating. Useproper tool when removing fuse.

Reinstall top cover, and close frontpanel.

1

1/4 in

Tools Needed:

5-3. Adjusting Spark Gaps

READ SAFETY BLOCKS at start ofSection 5 before proceeding.WARNING

Turn Off welding power source andcontrol unit, and disconnect inputpower.

1 Arc Starter Board PC8

Open front panel and remove topcover. Remove middle panel. Lo-cate spark gaps on PC8.

2 Tungsten End Of Point

Do not clean or dress tungsten. Re-place entire circuit board if tungstenend disappears.

3 Spark Gap

Normal spark gap is 0.028 in (0.711mm).

If spark gap is okay, reinstall middlepanel and top cover. Close frontcover. If adjustment is needed, con-tinue as follows:

4 Retaining Screw

Loosen screw. Place feeler gaugeof proper thickness in spark gap.

5 Pressure Point

Apply slight pressure at point untilgauge is held firmly in gap. Tightenretaining screw.

Reinstall middle panel and top cov-er. Close front panel.

Ref. ST- 146 844-A / S-0658

Tools Needed:

0.028 in (0.711 mm)

1/4 in

2

4

5

3

1

1

OM-2803 Page 22

5-4. Troubleshooting

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

• Turn Off welding power source and control unit, anddisconnect input power before inspecting,maintaining, or servicing.

HOT PARTS can cause severe burns.• Allow cooling period before maintaining or servicing.



boards or parts.

Troubleshooting to be performed only by qualifiedpersons.

WARNING

swarn8.1* 2/93

Trouble Remedy Section

Display dark; unit completely inopera-tive.

Be sure control unit and welding power source Power switches areOn.

4-12

Check for proper input power connections. 3-9

Check fuse F1 and replace if needed. 5-2

Erratic or improper weld output. Tighten all welding cable connections. 3-8

Check for proper size and type of cable. – –

Check for proper input and output connections. 3-8

Replace electrode. 12-1, 12-2

No high frequency; difficulty in establish-ing GTAW arc.

Be sure electrode holder cable is not close to any grounded metal. 11

Check cables and torch for cracked insulation or bad connections.Repair or replace necessary parts.

11

Check to make sure high frequency is enabled in program. 7-4

Check spark gaps and adjust if necessary. 5-3

Remote Pendant Control completely in-operative or working erratically.

Check connections to Remote 4 receptacle. 3-4

Check to make sure mode selector switch is in Automatic or Semi-Automatic.

4-6

Wandering arc; poor control of arcdirection.

Reduce gas flow rate. 4-11

Select proper size tungsten. 12-1

Properly prepare tungsten. 12-2

Tungsten electrode oxidizing and not re-maining bright after conclusion of weld.

Shield weld zone from drafts. – –

Increase postflow time. – –

Check and tighten all gas fittings. – –

Water in torch. Refer to torch Owner’s Manual for part(s) requiringreplacement, and repair torch as necessary.

– –

OM-2803 Page 23

SECTION 6 – INTRODUCTION TO PROGRAMMING

6-1. Introduction

A. General

Programs are created when parameters are defined in aseries of displays. Up to four programs can be createdper mode, for a total of sixteen programs. Programs canbe run individually, or can be linked or combined to run ina user-defined sequence.

When properly connected to the welding power source,this unit provides high frequency or scratch starting,preflow timing, start current level control and timing, ini-tial current level control and timing, initial slope timing,final slope timing, final current level control and timing,postflow timing, and amperage control of weld/peak cur-rent for either a pulsing or nonpulsing weld current.Pulsing controls include on/off selection, pulse peak lev-el control and timing, background current level controland timing, and pulse frequency and average currentcalculations. This unit also provides manual gas flowcontrol.

B. Weld Sequence

Ref. SB-139 983

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

Figure 6-1. Weld Sequence

In order to effectively use the control unit, it is necessaryto understand the weld sequence as it is shown inFigure 6-1. In most cases, some form of this weld se-quence is used in programming the control. Which stepsare programmable and what initiates each step variesfrom mode to mode.

The steps in the weld sequence are defined as follows:

Preflow: The period during which shielding gas flowsbefore an arc is established.

Start Level (Not Shown): A current level that can be pro-grammed to ease arc starting.

Initial Current: The beginning maintained current level.

Initial Slope: The ramping of the initial current up to theprogrammed weld/peak current level.

Weld/Peak Current: The programmed weld current lev-el (divided into peak and background current levelswhen pulsing is enabled).

Final Slope: The ramping down of weld/peak current tothe programmed final current level.

Final Current: The end current level just before the arc isextinguished.

Postflow: The period during which shielding gas flowsafter the arc has been extinguished.

6-2. Modes Of Operation

The control unit has four modes of operation: Automatic,Semi-Automatic, Manual GTAW, and SMAW. In abbre-viated form, the modes function as follows:

A. Automatic Mode (Figure 6-2)

A program that is created in the Automatic mode usesprogrammed information to control each step of theweld sequence. Pressing the Start/Increase push but-ton begins the sequence, with no more input requiredfrom the operator.

The operator has the ability to increase or decrease theweld amperage during weld/peak current within the de-fined amperage adjustment limits (see Section 3-2).This change does not affect the programmed values.Pressing the Stop push button at any time during theweld sequence halts program execution and sends thesequence directly to postflow.

Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

A: Momentary closure of Start/Increase push button beginssequence.

1. Preflow: Time programmed/Volume set by gas meter.2. Start Level (Not Shown): Time & level programmed.3. Initial Current: Time & level programmed.4. Initial Slope: Time programmed/Slope calculated by control

unit.5. Weld/Peak Current: Time & level programmed.6. Final Slope: Time programmed/Slope calculated by control

unit.7. Final Current: Time & level programmed.8. Postflow: Time programmed/Volume set by gas meter.

Stop push button functions throughout sequence.

Weld/peak current can be increased and/or decreased duringwelding.

Figure 6-2. Automatic Mode Sequence

OM-2803 Page 24

B. Semi-Automatic Mode

A program created in the Semi-Automatic mode con-trols certain portions of the weld sequence but requiresthe operator to control other portions. The Semi-Auto-matic mode has five variations. Which portions of thesequence the operator controls, and how the portionsare controlled depends on which variation is used.

Semi-Automatic 1 Mode (Figure 6-3):

In this mode, the end time for weld/peak current is notdefined. Pressing the Start/Increase push button beginsthe sequence. The program proceeds through eachstep into weld/peak current. The operator must signalthe end of weld/peak by pressing the Stop push button,at which time final slope begins.

The operator has the ability to increase or decrease theweld amperage during weld/peak current within the de-fined amperage adjustment limits (see Section 3-2).This change does not affect the programmed values.Pressing the Stop push button before weld/peak currenthalts program execution and sends the program directlyto postflow. Pressing the Stop push button after the endof weld/peak has been signalled has no effect.

Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

B


B: Momentary closure of Stop push button ends weld/peakcurrent.


unit.5. Weld/Peak Current: Time undefined/Level programmed.6. Final Slope: Time programmed/Slope calculated by control


Stop push button functions up to the signaled end of weld/peakcurrent.

Weld/peak current can be increased and/or decreased duringwelding.

Figure 6-3. Semi-Automatic 1 Mode Sequence


In this mode, time values are not defined for initial cur-rent, weld/peak current, and final current. The controlunit operates in a single button format. The operatorpresses the Start/Increase push button (or an equiva-lent user-wired push button) to start the program,presses it again to signal the end of initial current, pres-ses it again to signal the end of weld/peak current, andpresses it for a last time to signal the end of final current.

The weld amperage cannot be increased or decreasedonce the sequence has started, and the Stop push but-ton is not functional. The program goes directly topostflow if the arc is manually broken.

A: Momentary closure of *Start/Increase push button beginssequence.

B: Momentary closure of *Start/Increase push button ends ini-tial current.

C: Momentary closure of *Start/Increase push button endsweld/peak current.

D: Momentary closure of *Start/Increase push button ends fi-nal current.

*Or equivalent user-wired push button.

1. Preflow: Time programmed/Volume set by gas meter.2. Start Level (Not Shown): Time & level programmed.3. Initial Current: Time undefined/Level programmed.4. Initial Slope: Time programmed/Slope calculated by control


unit.7. Final Current: Time undefined/Level programmed.8. Postflow: Time programmed/Volume set by gas meter.

Stop push button is not functional throughout sequence.

Weld/peak current cannot be increased or decreased duringwelding.

Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

CB D


OM-2803 Page 25


This mode is similar to the Semi-Automatic 2 mode inthat time values are not defined for initial current, weld/peak current, and final current. The difference is in howthe operator signals the end of the weld sequence steps.The operator must press and hold the Start/Increasepush button (or an equivalent user-wired push button) tobegin the sequence. The Start/Increase push button isreleased to signal the end of initial current. The se-quence will then cycle through to weld/peak current. Theoperator must press and hold the Start/Increase pushbutton to signal the end of weld/peak current. The se-quence will then cycle through to final current. The endof final current is signaled when the operator releasesthe Start/Increase push button.

The weld amperage cannot be increased or decreasedonce the sequence has started, and the Stop push but-ton is not functional. The program goes directly topostflow if the arc is manually broken.

Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

CB D

A: Maintained closure of *Start/Increase push button beginssequence.

B: Release of *Start/Increase push button ends initial current.C: Maintained closure of *Start/Increase push button ends

weld/peak current.D: Release of *Start/Increase push button ends final current.


1. Preflow: Time programmed/Volume set by gas meter.2. Start Level (Not Shown): Time & level programmed.3. Initial Current: Time undefined/Level programmed.4. Initial Slope: Time programmed/Slope calculated by control


unit.7. Final Current: Time undefined/Level programmed.8. Postflow: Time programmed/Volume set by gas meter.





In this mode, time values are not defined for initial cur-rent, initial slope, weld/peak current, and final slope.Theoperator must use the Start/Increase and Decreasepush buttons (or equivalent user-wired push buttons) tovary the weld current level once initial current begins.

The first momentary closure of the Start/Increase pushbutton begins the sequence. Following arc initiation atinitial current, each time the Start/Increase push button

is pressed and held, weld output increases at a rate cal-culated by the control unit. The rate of increase dependson the programmed initial current level, weld/peak cur-rent level, and initial slope time. Each time the Decreasepush button is pressed and held, weld output decreasesat a rate calculated by the control unit. The rate of de-crease depends on the programmed weld/peak currentlevel, final current level, and final slope time. The weldoutput will maintain at the level that exists when eitherthe Start/Increase or Decrease push button is released.The programmed values that normally define the weld/peak current level define the upper limit that theStart/Increase push button can command.

The weld output level can be increased and decreasedindefinitely until the operator decreases the weld currentdown to the programmed final current level. At this pointthe sequence enters final current and then postflow. Ifthe weld current never exceeds the programmed finalcurrent value, the operator must decrease the weld cur-rent to zero, at which time postflow will begin.

The Stop push button is not functional in the Semi-Auto-matic 4 mode. The program goes directly to postflow ifthe arc is manually broken.

A: Momentary closure of *Start/Increase push button beginssequence.

B: Maintained closure of *Start/Increase push button in-creases weld output; maintained closure of *Decreasepush button decreases weld output.

C: Release of *Start/Increase or *Decrease push button setsweld/peak current (output remains at level existing whenpush button released).

D: Maintained closure of *Decrease push button decreasesweld output to programmed final current level; final currentbegins.


1. Preflow: Time programmed/Volume set by gas meter.2. Start Level (Not Shown): Time & level programmed.3. Initial Current: Time undefined/Level programmed.4. Initial Slope: Controlled by Start/Increase and Decrease

push buttons/Slope rate of change calculated by controlunit.

5. Weld/Peak Current: Time undefined/Level determined byweld output level when Start/Increase or Decrease pushbutton released.

6. Final Slope: Controlled by Start/Increase and Decreasepush buttons/Slope rate of change calculated by controlunit.

7. Final Current: Time & level programmed.8. Postflow: Time programmed/Volume set by gas meter.


Weld/peak current can be increased or decreased duringwelding.

Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

CB D


OM-2803 Page 26


This mode functions similarly to the Semi-Automatic 1mode, but in a single button format. A single momentaryclosure of the Start/Increase push button begins the se-quence. The program continues through theprogrammed sequence of events until weld/peak cur-rent. The operator must press the Start/Increase pushbutton to signal the end of weld/peak current, at whichtime final slope begins.

Unlike the Semi-Automatic 1 mode, the weld amperagecannot be increased or decreased once the sequencehas started, and the Stop push button is not functional.The program goes directly to postflow if the arc is manu-ally broken.


B: Momentary closure of Start/Increase push button endsweld/peak current.






Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

B


C. Manual GTAW Mode (Figure 6-8)

A Manual GTAW program requires the operator to per-form most of the control of the welding process. This iscarried out through the use of a remote control providingcontactor and amperage control (not the Remote Pend-

ant). High frequency is available for non-contact weldstarts.

Preflow begins when the remote contactor control isclosed. Following arc ignition, the weld sequence entersinitial current. Once initial current starts, the operatorcontrols the output level through the use of the remoteamperage control. The maximum output that can becommanded is defined when the program is created.The minimum value that can be commanded is the de-fined initial current level. Postflow begins when theremote contactor control is opened.

A: Closure of remote contactor control begins sequence.B: Arc ignition begins initial current.C: Opening of remote contactor control begins postflow.

1. Preflow: Time programmed/Volume set by gas meter.2. Start Level (Not Shown): Time & level programmed.3. Initial Current: Time undefined/Level programmed.4. Initial Slope:5. Weld/Peak Current:6. Final Slope:7. Final Current:8. Postflow: Time programmed/Volume set by gas meter.

Remote Pendant not used.

Weld/peak current can be increased or decreased duringwelding.

Not separate steps.Current level controlled by remoteamperage control.

Ref. SB-139 983

A

InitialCurrent


SlopeFinalSlope

FinalCurrent

Preflow Postflow

B C

Figure 6-8. Manual GTAW Mode Sequence

D. SMAW Mode

A program entered in the SMAW mode does not followthe weld sequence shown in Figure 6-1. When a remotecontactor control is closed, weld current is available. Astart level current may be programmed to help start thearc. Arc initiation and extinguishing are done manually.Weld output can be controlled remotely or kept at a de-fined level, depending on programmed parameters. Ifremote control is used, the maximum output that can becommanded is defined when the program is created.The minimum is the minimum value the welding powersource is capable of.

OM-2803 Page 27

SECTION 7 – PROGRAMMING

7-1. General

A. Displays

The displays presented by the control unit either provideinformation to the user or allow the user to enter infor-mation needed for program execution. The displaysvary from mode to mode. Within each mode, the dis-plays are always shown in the same sequence.

Pressing the Right/Increase push button allows the userto move forward through the sequence of displays, be-ginning to end. Pressing the Left/Decrease push buttonallows the user to move backward through the displays.Either push button can be used to access displays.

B. Selecting And Defining A Parameter

The user defines a parameter by entering a value for it.This is normally a three-step process (exceptions arenoted in the text), that is carried out as follows:

1. Press Parameter Select (see Section 4-7) to se-lect the parameter (the parameter will flash).

2. Press Right/Increase (see Section 4-8) or Left/Decrease (see Section 4-9) to enter the desiredvalue.

3. Press Parameter Select again to deselect the pa-rameter (the parameter will stop flashing). If thedisplay contains more than one parameter, thenext parameter will be selected.

Parameters are always selected in sequence. If the ex-isting value for the first parameter is acceptable, butanother parameter needs to be changed, use theParameter Select push button to select and deselect thefirst parameter without changing its value. The next dis-play in a mode cannot be accessed if a parameterremains selected (flashing) in the existing display.

C. Defining Program Number

In some displays, the first parameter is the programnumber. This number provides a means of identifyingprograms entered into the selected mode. Since param-eters are selected in sequence, even when the programnumber is not being changed it must be selected and de-selected before the next parameter can be changed.

The program number is normally defined in the first dis-play used to enter information. The defined number willcarry over to the following displays and does not need tobe redefined as long as the original defined number ap-plies.

To avoid unnecessary repetition,this manual does not indicate thatthe program number can be rede-fined in each display containing it. Itis assumed that when a program isentered, each display in sequenceapplies to the same program.

NOTE

D. Display Representation

When the control unit’s digital display is represented inthis Owner’s Manual, an “X” is used to represent a pa-rameter whose contents may vary, as shown in thefollowing example:

I N T E L L I S O F T

V E R S I O N X .X X

E. Initial Displays

Each time power is applied to the control unit or a reset isinitiated on the Program/Run/Reset key switch (seeSection 4-5), the initial displays are shown in sequence,each display shown once.

1. The first initial display indicates the defined weld-ing power source maximum current output. Thedisplay shows:

M A X. W E L D E R O U T P U T I S

S E T A T X X X .X A M P S

2. When the key switch is in the Program position,the maximum welder output parameter will auto-matically be selected. This value must match themaximum output of the welding power source be-ing used in order for the control unit to be properlycalibrated. If the value needs to be changed,press the Right/Increase or Left/Decrease pushbuttons as needed. After changing the parame-ter, or if the parameter does not need to bechanged, press Parameter Select to deselect it.

The next display will scroll into view.

3. The second initial display indicates the amperageadjustment limits that have been defined (seeSection 3-2). The value cannot be modifiedthrough this display. The display shows:

T H E A D J U S T M E N T L I M I T

I S + O R – X X A M P S

The next display will scroll into view.

4. The third initial display indicates the softwareVersion installed in the unit. The display shows:

I N T E L L I S O F T

V E R S I O N X .X X

The repeating displays will scroll into view.

OM-2803 Page 28

F. Repeating Displays (Ready Condition)

After the initial displays are shown, repeating displaysare shown. These displays will scroll continuously untilthe operator takes action. The presence of the repeatingdisplays indicates that the control unit is ready for a pro-gram to be entered, or for a program to be executed.

The program number in a displaycan be increased by pressing Pa-rameter Select while any of the re-peating displays are shown. This al-lows other programs to beaccessed.

NOTE

1. The first repeating display indicates the programnumber and that the control unit is ready for pro-gram execution. The display shows:

P R O G R A M # 0 X

U S E R E M O T E T O S T A R T

The next repeating display will scroll into view.

U S E I N C / D E C B U T T O N S

T O C H E C K P A R A M E T E R S

2. This display indicates that the Right/Increase andLeft/Decrease push buttons can be used to ac-cess the displays and verify parameter values.

The third repeating display will scroll into view.

U S E P A R A M E T E R S E L E C T

T O C H A N G E P R O G R A M #

3. This display explains the use of the ParameterSelect push button to change the program num-ber. This allows the creation of more than oneprogram per mode.

The first repeating display will scroll into view, andthe sequence will repeat.

7-2. Automatic Mode

NOTE If needed, see Section 7-1B for in-formation on selecting and defininga parameter.

Be sure to follow all applicablesteps, and only the applicablesteps, as determined by pro-grammed choices.

A. Procedure Up To Pulse Mode Selection

1. Apply power to the control unit, if applicable.

2. Place the Mode Selector switch in the Automaticposition.

3. Place the Program/Run/Reset key switch in theReset position, and then in the Program position.The display shows:



4. The maximum welder output parameter will auto-matically be selected. This value must match themaximum output of the welding power source be-ing used in order for the control unit to be properlycalibrated. If the value needs to be changed,press the Right/Increase or Left/Decrease pushbuttons as needed. After changing the parame-ter, or if the parameter does not need to bechanged, press Parameter Select to deselect it.

The remaining initial displays will be shown.

5. When the repeating displays (explained in Sec-tion 7-1F) are shown, press Right/Increase, andthe display shows:

# 0 X P R E F L O W

T I M E = X X .X

6. If applicable, define the program number (seeSection 7-1C). Define the shielding gas preflowtime as desired.

The range for preflow is 0.0 to 25.0 seconds, inincrements of 0.1 seconds.

7. Press Right/Increase, and the display shows:

# 0 X S T A R T L E V E L

T I M E = .X X X A M P S = X X X .X

8. Define the start level time and amperage valuesas desired.

When properly used, start level eases arc start-ing by allowing the use of an amperage value thatis higher than initial amperage for a short lengthof time.

The allowable range for the start level time is 0.0to 0.999 seconds, in increments of 0.001 sec-onds. The allowable range for the start levelamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.

OM-2803 Page 29


# 0 X I N I T I A L

T I M E = X X .X A M P S = X X X .X

10. Define the initial current level time and amperagevalues as desired.

The range for initial current level time is 0.0 to25.0 seconds, in increments of 0.1 seconds. Therange for initial current level varies from 0.0 to thedefined maximum weld output, in increments of0.1 amperes.


# 0 X I N I T I A L S L O P E

T I M E = X X .X

12. Define the initial slope time as desired.

The range for initial slope time is 0.0 to 25.0 sec-onds, in increments of 0.1 seconds.


* * P U L S E M O D E I S * *

> X X X <

14. Pressing Parameter Select toggles the displaybetween pulse mode On and pulse mode Off.Three possibilities exist at this point, as follows:

Pulse mode On is desired and peak current andbackground current are to be defined as time val-ues (see Step 15).

Pulse mode On is desired and peak current is tobe defined as a percentage of the total period(see Step 15).

Pulse mode Off is desired (see Step 16).

15. To define pulse mode On, proceed as follows:

a. Be sure the desired means of defining pulsemode has been selected according to Section3-2.

b. Use the Parameter Select push button to selectpulse mode On, and press Right/Increase toadvance to the next display while “On” is dis-played. The display shows:

# 0 X W E L D T I M E

T I M E = X X X .X

c. Define the weld current time as desired.

The allowable range for weld current time is 0.0to 999.9 seconds, in increments of 0.1 seconds.

d. Press Right/Increase. If peak current and back-ground current are being defined as timevalues, proceed to Section 7-2B. If peak currentis being defined as a percentage of the total pe-riod, proceed to Section 7-2C.

16. To define pulse mode Off, proceed as follows:

a. Use the Parameter Select push button to selectpulse mode Off, and press Right/Increase while“Off” is displayed. The display shows:

# 0 X W E L D T I M E

T I M E = X X X .X A M P S = X X X .X

b. Define the weld current time and amperage val-ues as desired.

The allowable range for weld current time is 0.0to 999.9 seconds, in increments of 0.1 seconds.The allowable range for the weld current valuevaries from 0.0 to the defined maximum welderoutput, in increments of 0.1 amperes.

c. Press Right/Increase, and proceed to Section7-2D.

B. Procedure With Pulse Mode On, Peak Current/Background Current Defined As Time Values

1. The display shows:

# 0 X P U L S E P E A K

T I M E = X .X X X A M P S = X X X .X

2. Define the pulse peak time and amperage valuesas desired.

The allowable range for the pulse peak time is 0.0to 9.999 seconds, in increments of 0.001 sec-onds. The allowable range for the pulse peakamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.


# 0 X P U L S E B A C K G R O U N D


4. Define the pulse background time and amperagevalues as desired.

The allowable range for the pulse backgroundtime is 0.0 to 9.999 seconds, in increments of0.001 seconds. The allowable range for the pulsebackground amperage value varies from 0.0 tothe defined maximum welder output, in incre-ments of 0.1 amperes.


# 0 X F R E Q U E N C Y =

X X .X X P U L S E S / S E C O N D

OM-2803 Page 30

6. This display is for informational purposes. It indi-cates the calculated frequency of pulses persecond.


# 0 X A V G C U R R E N T =

X X X .X A M P S

8. This display is for informational purposes. It indi-cates the calculated average current duringpulsing.

9. Press Right/Increase, and proceed to Section7-2D.

C. Procedure With Pulse Mode On, Peak CurrentDefined As A Percentage Of Total Period


# 0 X P U L S E F R E Q U E N C Y

P U L S E S / S E C O N D = X X X .X

2. Define the pulse frequency per second as de-sired.

The allowable range for the pulse frequency persecond is 0.0 to 500.0 pulses per second.

The increments the pulse frequency value is en-tered in changes according to the value that isentered. A value of 0.0 to 10.0 pulses per secondis entered in increments of 0.1 pulses per second.A value of 10.0 to 100.0 pulses per second is en-tered in increments of 1.0 pulses per second. Avalue greater than 100.0 pulses per second is en-tered in increments of 10.0 pulses per second.


# 0 X P U L S E P E A K T I M E

P E R C E N T P E A K = X X 0 %

4. Define the percentage of pulse time to be spent inpulse peak as desired.

The allowable range for the percentage of pulsetime that is to be spent in pulse peak is 0 to 100percent.

When a value up to and including 100.0 pulsesper second is programmed for the pulse frequen-cy, the pulse peak time value is entered inincrements of 1 percent. When a value greaterthan 100.0 pulses per second is programmed forthe pulse frequency, the pulse peak time value isentered in increments of 10 percent.



A M P S = X X X .X

6. Define the pulse peak amperage value as de-sired.

The allowable range for the pulse peak amper-age value varies from 0.0 to the definedmaximum welder output, in increments of 0.1 am-peres.



A M P S = X X X .X

8. Define the pulse background amperage value asdesired.

The allowable range for the pulse backgroundamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.



X X X .X A M P S


11. Press Right/Increase, and proceed to Section7-2D.

D. Procedure Following Pulse Mode Definition


# 0 X F I N A L S L O P E

T I M E = X X .X

2. Define the final slope time as desired.

The allowable range for the final slope time is 0.0to 25.0 seconds, in increments of 0.1 seconds.


# 0 X F I N A L


4. Define the final current time and amperage val-ues as desired.

The allowable range for the final current leveltime is 0.0 to 25.0 seconds, in increments of 0.1seconds. The allowable range for the final level

OM-2803 Page 31

amperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.


# 0 X P O S T F L O W

T I M E = X X .X

6. Define the shielding gas postflow time as desired.

The allowable range is 0.0 to 25.0 seconds, in in-crements of 0.1 seconds.

7. Press Right/Increase. A user relay #1 display willappear (user relays are explained in Section 3-6).Proceed to the display that matches what ap-pears and follow the applicable directions (eitherStep 8 or Step 10).

# 0 X U S E R R E L A Y # 1

> D I S A B L E D <

8. This display indicates that user relay #1 is dis-abled. If this is not the desired choice, proceed toStep 9. If this is the desired choice, press Right/Increase and proceed to Step 14.

9. If the desired choice is that user relay #1 be en-abled, proceed as follows:

a. Select Disabled.

b. Press Right/Increase, and the display shows:

# 0 X R E L A Y # 1 S T A R T

D E L A Y = X X X . X S E C .

10. This display indicates that user relay #1 is en-abled. If this is not the desired choice, proceed toStep 11. If this is the desired choice, proceed asfollows:

a. Define the length of start delay as desired.

The allowable range for the delay start time is0.0 to 120.0 seconds, in increments of 0.1seconds.

b. Press Right/Increase, and proceed to Step 12.

11. If the desired choice is that user relay #1 be dis-abled, proceed as follows:

a. Select the displayed delay value.

b. Either increase the displayed value to 120.0(using Right/Increase) or decrease the value to0.0 (using Left/Decrease), whichever value isclosest to the displayed value.

c. If the displayed value is now 120.0, press Right/Increase to disable user relay #1.

d. If the displayed value is now 0.0, press Left/De-crease to disable user relay #1.

e. Deselect Disabled.

f. Press Right/Increase, and proceed to Step 14.

# 0 X R E L A Y # 1 S T O P


12. This display allows the delay stop time to be de-fined. Define the delay stop time as desired.

The allowable range for the delay stop time is 0.0to 120.0 seconds, in increments of 0.1 seconds.


# 0 X U S E R R E L A Y # 2

> X X X X X X X X <

14. This display allows user relay #2 to be enabled ordisabled. To change the status of the relay, pro-ceed as follows:

a. Select the indicated choice (Enabled orDisabled).

b. Press either Right/Increase or Left/Decrease tochange the indicated choice.

c. When the desired choice is shown, deselect it.


V O L T / A M P M E T E R I N G

> X X X X X X X X <

16. Press Parameter Select to display the desiredchoice (Enabled or Disabled). Volt/amp meteringis explained in Section 4-4.

17. When the desired choice is shown, press Right/Increase to advance to the next display. Thedisplay shows:

* * * * * * D R Y R U N * * * * * *


18. If desired, press Start/Increase on the RemotePendant to carry out a dry run of the program (seeSection 7-7 for information on the Dry Run fea-ture). To place the control unit in the Readycondition, press Right/Increase.

19. In the Ready condition the control unit is ready tohave another program entered or to execute aprogram. For information on entering a programinto the desired mode, refer to the applicable sub-section in this Section. For information on

OM-2803 Page 32

executing a program, refer to the applicable sub-section in Section 8.

7-3. Semi-Automatic Mode

If needed, see Section 7-1B for in-formation on selecting and defininga parameter.


This section covers program entryin all five Semi-Automatic modes.Differences between one mode andanother are stated. Be sure the de-sired Semi-Automatic mode hasbeen defined on DIP switch SW1(see Section 3-2) before using thefollowing procedure to enter aprogram.

NOTE



2. Place the Mode Selector switch in the Semi-Automatic position.





5. The remaining initial displays (explained inSection 7-1E) will be shown.

6. When the repeating displays (explained inSection 7-1F) are shown, press Right/Increase,and the display shows:

# 0 X P R E F L O W

T I M E = X X .X










a. For Semi-Automatic 1 and 5 modes:

# 0 X I N I T I A L


b. For Semi-Automatic 2, 3, and 4 modes:

# 0 X I N I T I A L

A M P S = X X X .X

11. Define the initial current level time (if applicable)and amperage values as desired.

The allowable range for the initial current leveltime is 0.0 to 25.0 seconds, in increments of 0.1seconds. The allowable range for the initial cur-rent amperage value varies from 0.0 to thedefined maximum welder output, in increments of0.1 amperes.


# 0 X I N I T I A L S L O P E

T I M E = X X .X

13. Define the initial slope time as desired.

The allowable range for the initial slope time is 0.0to 25.0 seconds, in increments of 0.1 seconds.


OM-2803 Page 33

* * P U L S E M O D E I S * *

> X X <







b. Use the Parameter Select push button to selectpulse mode On, and press Right/Increase toadvance to the next display while “On” is dis-played.

c. If peak current and background current are be-ing defined as time values, proceed to Section7-3B. If peak current is being defined as a per-centage of the total period, proceed to Section7-3C.

17. To define pulse mode Off, proceed as follows:

a. Use the Parameter Select push button to selectpulse mode Off, and press Right/Increase while”Off” is displayed. The display shows:

# 0 X W E L D

A M P S = X X X .X

b. Define the weld current value as desired.

The allowable range for the weld current valuevaries from 0.0 to the defined maximum welderoutput, in increments of 0.1 amperes.

c. Press Right/Increase. Proceed to Section 7-3Dif programming in Semi-Automatic 1 or 5modes. Proceed to Section 7-3E if program-ming in Semi-Automatic 2, 3, or 4 modes.





2. Define the pulse peak time and amperage valuesas desired.

The allowable range for the pulse peak time is 0.0to 9.999 seconds, in increments of 0.001 sec-onds. The allowable range for the pulse peakamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.




4. Define the pulse background time and amperagevalues as desired.

The allowable range for the pulse backgroundtime is 0.0 to 9.999 seconds, in increments of0.001 seconds. The allowable range for the pulsebackground amperage value varies from 0.0 tothe defined maximum welder output, in incre-ments of 0.1 amperes.







X X X .X A M P S


9. Press Right/Increase. Proceed to Section 7-3D ifprogramming in Semi-Automatic 1 or 5 modes.Proceed to Section 7-3E if programming in Semi-Automatic 2, 3, or 4 modes.

OM-2803 Page 34






The allowable range for the pulse frequency persecond is 0.0 to 500.0 pulses per second.

The increments the pulse frequency value is en-tered in changes according to the value that isentered. A value of 0.0 to 10.0 pulses per secondis entered in increments of 0.1 pulses per second.A value of 10.0 to 100.0 pulses per second is en-tered in increments of 1.0 pulses per second. Avalue greater than 100.0 pulses per second is en-tered in increments of 10.0 pulses per second.





The allowable range for the percentage of pulsetime that is to be spent in pulse peak is 0 to 100percent.

When a value up to and including 100.0 pulsesper second is programmed for the pulse frequen-cy, the pulse peak time value is entered inincrements of 1 percent. When a value greaterthan 100.0 pulses per second is programmed forthe pulse frequency, the pulse peak time value isentered in increments of 10 percent.



A M P S = X X X .X

6. Define the pulse peak amperage value as de-sired.

The allowable range for the pulse peak amper-age value varies from 0.0 to the definedmaximum welder output, in increments of 0.1 am-peres.



A M P S = X X X .X

8. Define the pulse background amperage value asdesired.

The allowable range for the pulse backgroundamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.



X X X .X A M P S


11. Press Right/Increase. Proceed to Section 7-3D ifprogramming in Semi-Automatic 1 or 5 modes.Proceed to Section 7-3E if programming in Semi-Automatic 2, 3, or 4 modes.

D. Procedure Following Pulse Mode Definition ForSemi-Automatic 1 And 5 Modes



T I M E = X X .X


The allowable range for the final slope time is 0.0to 25.0 seconds, in increments of 0.1 seconds.Define the final slope time as desired.


# 0 X F I N A L


4. Define the final current time and amperage val-ues as desired.

The allowable range for the final current leveltime is 0.0 to 25.0 seconds, in increments of 0.1seconds. The allowable range for the final levelamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.



T I M E = X X .X

OM-2803 Page 35


The allowable range is 0.0 to 25.0 seconds, inincrements of 0.1 seconds.

7. Press Right/Increase. A user relay #1 display willappear (user relays are explained in Section 3-6).Proceed to the display that matches what ap-pears and follow the applicable directions (eitherStep 8 or Step 10).

# 0 X U S E R R E L A Y # 1

> D I S A B L E D <

8. This display indicates that user relay #1 is dis-abled. If this is not the desired choice, proceed toStep 9. If this is the desired choice, press Right/Increase and proceed to Step 14.

9. If the desired choice is that user relay #1 beenabled, proceed as follows:

a. Select Disabled.

b. Press Right/Increase, and the display shows:

# 0 X R E L A Y # 1 S T A R T


10. This display indicates that user relay #1 is en-abled. If this is not the desired choice, proceed toStep 11. If this is the desired choice, proceed asfollows:

a. Define the length of start delay as desired.

The allowable range for the delay start time is0.0 to 120.0 seconds, in increments of 0.1seconds.

b. Press Right/Increase, and proceed to Step 12.

11. If the desired choice is that user relay #1 be dis-abled, proceed as follow:

a. Select the displayed delay value.

b. Either increase the displayed value to 120.0(using Right/Increase) or decrease the value to0.0 (using Left/Decrease), whichever value isclosest to the displayed value.

c. If the displayed value is now 120.0, press Right/Increase to disable user relay #1.

d. If the displayed value is now 0.0, press Left/Decrease to disable user relay #1.

e. Deselect Disabled.

f. Press Right/Increase, and proceed to Step 14.

# 0 X R E L A Y # 1 S T O P


12. This display allows the delay stop time to be de-fined. Define the delay stop time as desired.

The allowable range for the delay stop time is 0.0to 120.0 seconds, in increments of 0.1 seconds.


# 0 X U S E R R E L A Y # 2

> X X X X X X X X <

14. This display allows user relay #2 to be enabled ordisabled. To change the status of the relay, pro-ceed as follows:

a. Select the indicated choice (Enabled orDisabled).

b. Press either Right/Increase or Left/Decrease tochange the indicated choice.

c. When the desired choice is shown, deselect it.



> X X X X X X X X <


17. When the desired choice is shown, press Right/Increase to advance to the next display. Thedisplay shows:

* * * * * * D R Y R U N * * * * * *


18. If desired, press Start/Increase on the RemotePendant to carry out a dry run of the program (seeSection 7-7 for information on the Dry Run fea-ture). To place the control unit in the Readycondition, press Right/Increase.

19. In the Ready condition the control unit is ready tohave another program entered or to execute aprogram. For information on entering a programinto the desired mode, refer to the applicable sub-section in this Section. For information onexecuting a program, refer to the applicable sub-section in Section 8.

E. Procedure Following Pulse Mode Definition ForSemi-Automatic 2, 3, And 4 Modes



T I M E = X X .X


The allowable range for the final slope time is 0.0to 25.0 seconds, in increments of 0.1 seconds.Define the final slope time as desired.

OM-2803 Page 36


a. For Semi-Automatic 2 and 3 modes:

# 0 X F I N A L

A M P S = X X X .X

b. For Semi-Automatic 4 mode:

# 0 X F I N A L


4. Define the final current time (if applicable) andamperage values as desired.

The allowable range for the final current time is0.0 to 25.0 seconds, in increments of 0.1 sec-onds. The allowable range for the final currentamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.



T I M E = X X .X





> X X X X X X X X <


9. When the desired choice is shown, press Right/Increase. The control unit will enter the Readycondition.


7-4. Manual GTAW Mode



NOTE



2. Place the Mode Selector switch in the ManualGTAW position.






6. When the repeating displays are shown (seeSection 7-1F), press Right/Increase, and thedisplay shows:

H I G H F R E Q U E N C Y I S

> X X X X X X X <

7. Pressing Parameter Select toggles the displaybetween high frequency Enabled and high fre-quency Disabled. Whichever option is showingwhen this display is exited will be in effect. UseParameter Select to display the desired option(Enabled or Disabled).

With high frequency enabled, the control unit pro-vides a high frequency arc start for a non-contactweld start. High frequency should be disabled if atouch or scratch start is desired.

8. If high frequency is enabled, proceed to Step 9. Ifhigh frequency is disabled, proceed directly toStep 13.

OM-2803 Page 37


# 0 X P R E F L O W

T I M E = X X .X










# 0 X I N I T I A L

A M P S = X X X .X

14. The value entered in this display not only definesthe initial amperage current, but also acts to de-fine the minimum current output that can becommanded on the remote amperage control.Define the initial current level value as desired.

The allowable range for the initial current levelvalue varies from 0.0 to the defined maximumwelder output, in increments of 0.1 amperes.


* * P U L S E M O D E I S * *

> X X <







b. Use the Parameter Select push button to selectpulse mode On, and press Right/Increase toadvance to the next display while “On” is dis-played.

c. If peak current and background current are be-ing defined as time values, proceed to Section7-4B. If peak current is being defined as a per-centage of the total period, proceed to Section7-4C.

18. To define pulse mode Off, use the Parameter Se-lect push button to select pulse mode Off, andpress Right/Increase while “Off” is displayed.Proceed to Section 7-4D.



# 0 X M A X P U L S E P E A K


2. The value entered in this window defines themaximum peak current output that can be com-manded on the remote amperage control. Definethe maximum pulse peak time and amperage val-ues as desired.

The allowable range for the maximum pulse peaktime is 0.0 to 9.999 seconds, in increments of0.001 seconds. The allowable range for the maxi-mum pulse peak amperage value varies from 0.0to the defined maximum welder output, in incre-ments of 0.1 amperes.


# 0 X M A X P U L S E B A C K G N D


4. The value entered in this window defines themaximum background current output that can becommanded on the remote amperage control.Define the pulse background time and amperagevalues as desired.

The allowable range for the maximum pulsebackground time is 0.0 to 9.999 seconds, in incre-ments of 0.001 seconds. The allowable range forthe maximum pulse background amperage valuevaries from 0.0 to the defined maximum welderoutput, in increments of 0.1 amperes.

OM-2803 Page 38







T I M E = X X .X



9. Press Right/Increase. The control unit will enterthe Ready condition.







The allowable range for the pulse frequency persecond is 0.0 to 500.0 pulses per second, in in-crements of 10 pulses per second.





The allowable range for the percentage of pulsetime that is to be spent in pulse peak is 0 to 100percent, in increments of 10 percent.


# 0 X M A X P U L S E P E A K

L E V E L = X X X .X A M P S

6. The value entered in this window defines themaximum peak current output that can be com-manded on the remote amperage control. Definethe maximum pulse peak amperage value asdesired.

The allowable range for the maximum pulse peakamperage value varies from 0.0 to the definedmaximum welder output, in increments of 0.1amperes.


# 0 X M A X P U L S E B A C K G N D

L E V E L = X X X .X A M P S

8. The value entered in this window defines themaximum background current output that can becommanded on the remote amperage control.Define the maximum pulse background amper-age value as desired.

The allowable range for the maximum pulsebackground amperage value varies from 0.0 tothe defined maximum welder output, in incre-ments of 0.1 amperes.



T I M E = X X .X





D. Procedure With Pulse Mode Off


# 0 X M A X W E L D L E V E L

A M P S = X X X .X

OM-2803 Page 39

2. The maximum weld level is the maximum weldcurrent that can be commanded on the remoteamperage control. Define the maximum weldcurrent level as desired.




T I M E = X X .X


The allowable range is 0.0 to 25.0 seconds, inincrements of 0.1 seconds.


6. In the Ready condition, the control unit is ready tohave another program entered or to execute aprogram. For information on entering a programinto the desired mode, refer to the applicable sub-section in this Section. For information onexecuting a program, refer to the applicable sub-section in Section 8.

7-5. SMAW Mode


NOTE


2. Place the Mode Selector switch in the SMAWposition.






6. When the repeating displays (explained inSection 7-1F) are shown, press Right/Increase,and the display shows:



7. If applicable, define the program number (seeSection 7-1C). Define the start level time and am-perage values as desired.




R E M O T E I S

> X X X X X X X <

9. Pressing Parameter Select toggles the displaybetween Remote Enabled and Remote Disabled.When Remote is enabled, weld amperage can bevaried by a remote amperage control device up tothe user-defined maximum weld current level.When Remote is disabled, the program sets weldcurrent at the level defined in the Weld Leveldisplay.

Whichever option is showing when this display isexited will be in effect. Use the Parameter Selectpush button to display the desired option(Enabled or Disabled).

10. Press Right/Increase with the desired remoteamperage control option showing. If remote am-perage control is enabled, proceed to Step 11. Ifremote amperage control is disabled, proceed toStep 14.

11. When remote amperage control is enabled, thedisplay shows:

# 0 X M A X W E L D L E V E L

A M P S = X X X .X

12. The maximum weld level is the maximum weldcurrent that can be commanded on the remoteamperage control. Define the maximum weldcurrent level as desired.


OM-2803 Page 40

13. Proceed to Step 16.

14. When remote amperage control is disabled, thedisplay shows:

# 0 X W E L D L E V E L

A M P S = X X X .X

15. Define the weld current level as desired.



17. In the Ready condition, the control unit is ready tohave another program entered or to execute aprogram. For information on entering a programinto the desired mode, refer to the applicable sub-section in this Section. For information onexecuting a program, refer to the applicable sub-section in Section 8.

7-6. Editing A Program

To edit an existing program, carry out the following:


2. Use the Mode Selector switch to select the modeof the program to be edited.

3. Place the Program/Run/Reset key switch in theProgram position.

4. When the repeating displays are shown, pressthe Right/Increase or Left/Decrease push buttonuntil the display to be edited is shown.

5. Edit the desired parameter(s). If needed, seeSection 7-1B for information on selecting and de-fining parameters. See Section 7-1C forinformation on changing the program number in adisplay to access multiple programs.

6. Continue accessing displays and editing param-eters until editing is complete. The newly enteredparameters become a part of the program assoon as they are entered.

7. To lock out program changes and prepare for pro-gram execution, place the Program/Run/Resetkey switch in the Run position.

8. To prepare for program execution while remain-ing in Program, press Right/Increase orLeft/Decrease until the Ready condition is active(see Section 7-1F).

7-7. Dry Run FeatureThe Dry Run feature allows a program to be verified byexecuting it without actually establishing an arc. All tim-ing and contact closures are performed without gas,high frequency, or power source contactor beingactivated.

The Dry Run feature is only available in the Automaticmode and Semi-Automatic 1 or 5 modes. When used inthe Semi-Automatic 1 or 5 modes, the weld time willcontinue to increment until the Start/Increase on the Re-mote Pendant is pressed.

If volt/amp metering (see Section 4-4) is enabled, it willnot be active when a dry run of the program is carriedout.

To use the Dry Run feature, proceed as follows:

1. Access the Dry Run display.

2. Press Start/Increase on the Remote Pendant tobegin the dry run execution.

3. The control unit will perform a dry run of the pro-gram. The dry run stops automatically when theprogrammed postflow time elapses. To stop thedry run before completion, press the Stop pushbutton.

7-8. Stop Watch FeatureThe stop watch feature is a part of Dry Run when DryRun is used in the Automatic mode. Stop watch allowsthe operator to define the end of weld time by pressingthe Start/Increase push button. This allows the operatorto observe fixturing during a dry run and define the endof weld time relative to actual positions.

To use the stop watch feature, proceed as follows:

1. Enter a 0 (zero) for weld time when entering aprogram in the Automatic mode.

2. Carry out a dry run of the entered program.

3. When the desired end of weld time is reached,press Start/Increase on the Remote Pendant.The time displayed when the push button ispressed becomes the weld time value in the pro-gram and will remain so until changed.

7-9. Linking Programs

The Link feature is only available inthe following modes: Automatic,Semi-Automat ic 1, and Semi-Automatic 5.

NOTE

Existing programs in the required modes can be linkedtogether so that the next program in sequence beginswhen Start/Increase is pressed on the Remote Pend-ant. Up to four programs can be linked. All linkedprograms must be in the same mode of operation. Thefirst program desired in the chain of programs is as-signed to position one, the second desired program isassigned to position two, etc. A reset is assigned to theLink position following the last program to signal the endof the linked programs.

If four programs are linked together,it is not necessary for the user to as-sign a reset. A reset is permanentlyassigned to the fifth Link position.

NOTE

For example, to run program 2, then program 1, and fi-nally program 4, program 2 would be assigned to link

OM-2803 Page 41

position one, program 1 would be assigned to positiontwo and program 4 would be assigned to position three.A reset would be assigned to position four to indicate theend of the linked programs.

When the Link mode is entered, three displays are re-peated in sequence. This indicates that the Link Readycondition is active. These displays must be present inorder to start execution of the linked programs.

To link programs, proceed as follows:

1. Be sure one of the proper modes is selected (seeNote at beginning of this section).

2. Place the Program/Run/Reset key switch in theProgram position.

3. Call up the following display (this is one of the re-peating displays explained in Section 7-1F).

P R O G R A M # 0 X


4. Press Parameter Select to increase the programnumber beyond 4. The following repeating Linkmode displays appear:

P R O G R A M “ L I N K ” M O D E



T O C H A N G E T H E L I N K S


T O E X I T “ L I N K ” M O D E


L I N K P O S I T I O N X X

I S X X X X X X X

6. The Link position (1 through 4) is indicated in theupper right corner. The second line indicates theprogram number (or Reset) assigned to theposition.

7. To change the number of the Link position, selectit and press either Right/Increase or Left/De-crease to change the value as desired. As theLink position numbers change, the program num-ber currently assigned to that position will bedisplayed in the second line.

8. To change the program number assigned to aLink position, select the program number andpress either Right/Increase or Left/Decrease tochange the value.

Reset follows program number 04. To assign Re-set to a Link position, select the program numberand press Right/Increase repeatedly to go be-yond program number 04. To assign a numberwhen Reset is displayed, select Reset and pressLeft/Decrease.

9. Repeat Steps 7 and 8 as needed to define the de-sired program number for each Link positionbeing used.

10. Select the Link Position number in the upper rightcorner of the display, and press Right/Increase orLeft/Decrease to display the number of the firstLink position to be executed when the program isrun.

The Link position shown when theLink mode is exited will be the firstposition executed when the Linkprograms are run. Be sure the de-sired Link position is showing beforeexiting the Link mode.

NOTE

11. Press Right/Increase when there are no parame-ters selected in the Link Position display. Therepeating Link mode displays will appear.

12. Press Parameter Select while the repeating dis-plays are shown to exit the Link mode. Thedisplay shows:

“ C O M B I N E ” M O D E


13. If desired, use the Combine mode as explained inSection 7-10. To exit the Combine mode withoutusing it, press Parameter Select while this dis-play is shown. The control unit will enter theReady condition.

7-10. Combining Programs

The Combine feature is only avail-able in the fol lowing modes:Automatic, Semi-Automatic 1, andSemi-Automatic 5.

NOTE

The Combine feature uses parameters from severalprograms to create a single multi-slope weld program.The first program defines preflow, initial amperage, ini-tial to weld amperage slope, and the weld amperage.Following specified programs provide weld to weldslopes and weld times. The weld to weld slopes are cal-culated by the control unit. The last program providesthe final slope, and final amperage and postflow values.This is useful in applications using multiple non-stop

OM-2803 Page 42

passes, such as pipe-welding with the use of a seam-tracker.

When the Combine mode is entered, three displays arerepeated in sequence, indicating that the CombineReady condition is active. These displays must be pre-sent in order to start execution of the combinedprograms.

To combine programs, proceed as follows:

1. Be sure one of the proper modes is selected (seeNOTE at beginning of this section).

2. Call up the following display (this is one of the re-peating displays explained in Section 7-1F).

P R O G R A M # 0 X


3. Press Parameter Select to increase the programnumber beyond 4. The following repeating Linkmode display appears:

P R O G R A M “ L I N K ” M O D E


4. Press Parameter Select to enter the Combinemode. The following repeating Combine modedisplays appear:

“ C O M B I N E ” M O D E



T O E N T E R C H A N G E S


T O E X I T “ C O M B I N E ”


C O M B I N E P O S I T I O N X X

I S X X X X X X X

6. The Combine position (1 through 4) is indicated inthe upper right corner. The second line indicatesthe program number (or Reset) assigned to theposition.

7. To change the number of the Combine position,select it and press either Right/Increase or Left/Decrease to change the value as desired. As theCombine position numbers change, the programnumber currently assigned to that position will bedisplayed in the second line.

8. To change the program number assigned to aCombine position, select the program numberand press either Right/Increase or Left/Decreaseto change the value.

Reset follows program number 04. To assign Re-set to a Combine position, select the programnumber and press Right/Increase repeatedly togo beyond program number 04. To assign a num-ber when Reset is displayed, select Reset andpress Left/Decrease.

If four programs are combined to-gether, it is not necessary for theuser to assign a reset. A reset is per-manently assigned to the fifth Com-bine position.

NOTE

9. Repeat Steps 7 and 8 as needed to define the de-sired program number for each Combine positionbeing used.

10. Press Right/Increase when there are no parame-ters selected in the Combine Position display.The display shows:

* D R Y R U N “ C O M B I N E ” *


11. If desired, press Start/Increase on the RemotePendant to carry out a dry run of the combinedprogram (see Section 7-7 for information on theDry Run feature). To exit the Combine mode,press Right/Increase, and then Parameter Selectwhen the repeating Combine mode displays areshown. The control unit will enter the Readycondition.

OM-2803 Page 43

SECTION 8 – SEQUENCE OF OPERATION

WARNINGELECTRIC SHOCK can kill.• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Do not touch live electrical parts.

• Keep all panels and covers securely in place.

FUMES AND GASES can be hazardousto your health.• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) andmanufacturer’s instructions for material used.

WELDING can cause fire or explosion.• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;NOISE can damage hearing.• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.


• Keep all doors, panels, covers, and guards closedand securely in place.

MAGNETIC FIELDS FROM HIGH CUR-RENTS can affect pacemaker operation.• Pacemaker wearers keep away.

• Wearers should consult their doctor before goingnear arc welding, gouging, or spot welding opera-tions.

See Safety Precautions at beginning of manual for ba-sic welding safety information. swarn6.1 10/91

8-1. Gas Tungsten Arc Welding (GTAW) InThe Automatic Mode

WARNING: Read and follow safety informa-tion at beginning of entire Section 8 beforeproceeding.

1. Be sure welding power source and related equip-ment are installed as instructed in theirrespective Owner’s Manuals.

2. Install control unit according to Section 3.

3. Be sure desired weld program (or programs) hasbeen entered into control unit.

4. Place Mode Selector switch in Automaticposition.

5. Select and prepare tungsten electrode accordingto Section 12.

6. Insert electrode into torch.

7. Wear dry insulating gloves and clothing.

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

9. Turn on shielding gas supply at source.

10. Wear welding helmet with proper filter lens ac-cording to ANSI Z49.1.

11. Energize welding power source and control unit.

12. Begin welding, observing the following:

a. Be sure the desired program is active before ex-ecuting a program. The active program isindicated in the applicable repeating display(see Section 7-1F). To select a different pro-gram, press Parameter Select while the

repeating displays are shown. This will increasethe program number.

b. When the unit is in the Ready condition (seeSection 7-1F), momentarily press Start/Increase to begin the weld sequence.

c. If volt/amp metering (see Section 4-4) isenabled, the control unit will display the weldvoltage and amperage values while welding. Ifvolt/amp metering is disabled, the weld se-quence displays will be shown, with time valueschanging to reflect events being carried out.

d. During the Weld Time portion of the program,the Start/Increase or Decrease push buttonsmay be pressed and held to modify the weldcurrent level within the defined amperage ad-justment limits (see Section 3-2). Theprogrammed values will not be affected.

e. At any time, the Stop push button may bepressed to end the weld sequence prematurelyand send the program to postflow.

f. After postflow is timed out, the control unit willreturn to the Ready condition and wait for thenext closure of the Start/Increase push button.If Start/Increase is pressed during postflow, theprogram will restart the weld sequence from thebeginning without preflow timing.

8-2. Gas Tungsten Arc Welding (GTAW) InThe Semi-Automatic Modes


OM-2803 Page 44

A. Shared Initial Procedure




4. Be sure desired Semi-Automatic mode is se-lected on DIP switch SW1 (see Section 3-2).

5. Place Mode Selector switch in Semi-Automaticposition.




9. Connect work clamp to clean, bare metal at work-piece.



12. Be sure applicable remote control device is con-nected as follows:

a. Semi-Automatic 1 Mode:

Connect Remote Pendant to Remote 4 recep-tacle RC2.

b. Semi-Automatic 2 Mode:

Connect Remote Pendant (or equivalent Startpush button [see Section 3-4]) to Remote 4receptacle RC2.

c. Semi-Automatic 3 Mode:

Connect Remote Pendant (or equivalent Startpush button [see Section 3-4]) to Remote 4receptacle RC2.

d. Semi-Automatic 4 Mode:

Connect Remote Pendant (or equivalent Start/Increase and Decrease push buttons [seeSection 3-4]) to Remote 4 receptacle RC2.

e. Semi-Automatic 5 Mode:

Do not make connections to Remote 4 recep-tacle RC2 at this time.


14. If using the Semi-Automatic 5 mode, connectRemote Pendant to Remote 4 receptacle RC2 atthis time.

15. Be sure the desired program is active before ex-ecuting a program. The active program isindicated in the applicable repeating display (seeSection 7-1F). To select a different program,press Parameter Select while the repeating dis-plays are shown. This will increase the programnumber.

16. Begin welding, observing the operation proce-dures for the applicable Semi-Automatic mode(see Sections 8-2B through 8-2F).

17. In all Semi-Automatic modes, if volt/amp meter-ing (see Section 4-4) is enabled, the control unitwill display the weld voltage and amperage val-ues while welding. If volt/amp metering isdisabled, the weld sequence displays will beshown, with time values changing to reflectevents being carried out.

B. Operation Procedures For Semi-Automatic 1Mode

1. When the unit is in the Ready condition (seeSection 7-1F), momentarily press Start/Increaseto begin the weld sequence.

2. During the Weld Time portion of the program, theStart/Increase or Decrease push buttons may bepressed and held to modify the weld current levelwithin the defined amperage adjustment limits(see Section 3-2). The programmed values willnot be affected.

3. Before the weld sequence reaches Weld Time,the Stop push button may be pressed to end theprogram prematurely and send the weld se-quence to postflow.

4. The Stop push button must be pressed duringWeld Time to signal the end of weld/peak current.When Stop is pressed, the weld sequence will en-ter final slope. Once Weld Time is terminated, theStop push button has no affect on program oper-ation.

5. After postflow is timed out, the control unit returnsto the Ready condition and waits for the next clo-sure of the Start/Increase push button. IfStart/Increase is pressed during postflow, theprogram will restart the weld sequence from thebeginning without preflow timing.

C. Operation Procedures For Semi-Automatic 2Mode

In the Semi-Automatic 2 mode, auser-wired Start push button maybe used instead of the RemotePendant to control the weld se-quence. If this is being done, substi-tute “user-wired Start push button”for “Start/Increase push button” inthis subsection.

NOTE

1. When the unit is in the Ready condition (seeSection 7-1F), momentarily press Start/Increaseto begin the weld sequence. After arc initiation atinitial current, the control unit will maintain theprogrammed initial current value.

2. Start/Increase must be pressed to signal the endof initial time and the beginning of initial slope.Following initial slope, the control unit will main-tain Weld Time current.

OM-2803 Page 45

3. Start/Increase must be pressed to signal the endof Weld Time and the beginning of final slope.Following final slope, the control unit will maintainthe arc at the final current level

4. Start/Increase must be pressed to signal the endof final current and the beginning of postflow.


6. The Stop push button is not functional in thismode. However, the existence of the arc is moni-tored by the control unit. If the arc is manuallybroken, the program will go directly to postflow.

D. Operation Procedures For Semi-Automatic 3Mode

In the Semi-Automatic 3 mode, auser-wired Start push button maybe used instead of the RemotePendant to control the weld se-quence. If this is being done, substi-tute “user-wired Start push button”for “Start/Increase push button” inthis subsection.

NOTE

1. When the unit is in the Ready condition (seeSection 7-1F), press and hold the Start/Increasepush button to begin the weld sequence. After arcinitiation at initial current, the control unit willmaintain the programmed initial current value.

2. Release the Start/Increase to signal the end ofinitial time and the beginning of initial slope. Fol-lowing initial slope, the control unit will maintainthe programmed weld current.

3. Press and hold Start/Increase to signal the end ofWeld Time and the beginning of final slope. Fol-lowing final slope, the control unit will maintain thearc at the final current level.

4. Release Start/Increase to indicate the end of finalcurrent and the beginning of postflow.

5. After postflow is timed out, the control unit returnsto the Ready condition and waits for the nextmaintained closure of the Start/Increase pushbutton. If Start/Increase is pressed and held dur-ing postflow, the program will restart the weldsequence from the beginning without preflowtiming.


E. Operation Procedures For Semi-Automatic 4Mode

In the Semi-Automatic 4 mode, us-er-wired Start/Increase and De-crease push buttons may be usedinstead of the Remote Pendant tocontrol the weld sequence.

NOTE

1. When the unit is in the Ready condition (seeSection 7-1F), momentarily press Start/Increaseto begin the weld sequence. After arc initiation atinitial current, the control unit will maintain theprogrammed initial current value.

Program execution at this point varies accordingto whether pulsing is enabled or disabled. Pro-ceed to Step 2 if pulsing is enabled, and Step 3 ifpulsing is disabled.

2. When pulsing is enabled:

a. Press and hold Start/Increase to increase theweld current output. The peak current outputwill increase at a rate determined by the pro-grammed value of initial current level, initialslope time, and peak current level. The back-ground current output will increase at a ratedetermined by the programmed value of initialcurrent level, initial slope time, and backgroundcurrent level.

b. When Start/Increase is released, the peak andbackground current levels that exist when thepush button is released will be maintained.

c. The programmed value of peak and back-ground current levels define the maximum limitthat the Start/Increase push button can com-mand.

d. Press and hold the Decrease push button to de-crease the weld current output. The peakcurrent output will decrease at a rate deter-mined by the programmed value of peakcurrent, final slope time, and final current level.The background current output will decrease ata rate determined by the programmed value ofbackground current, final slope time, and finalcurrent level.

e. When Decrease is released, the peak andbackground current levels that exist when thepush button is released will be maintained.

f. Increasing and decreasing the pulsed weld cur-rent output can go on indefinitely.

g. If the weld current output is decreased to thevalue programmed for final current, the pro-gram will enter final current and proceed topostflow.

h. If weld current never exceeds the programmedvalue for final current, the weld current must bemanually decreased to zero, at which time theprogram will begin postflow.

OM-2803 Page 46

3. When pulsing is disabled:

a. Press and hold the Start/Increase to increasethe weld current output. The output will in-crease at a rate determined by the programmedvalue of initial current level, initial slope time,and weld current level.

b. When Start/Increase is released, the weld cur-rent level that exists when the push button isreleased will be maintained.

c. The programmed weld current value definesthe maximum limit the Start/Increase push but-ton can command.

d. Press and hold the Decrease push button to de-crease the weld current output. The output willdecrease at a rate determined by the pro-grammed value of weld current, final slopetime, and final current level.

e. When Decrease is released, the weld currentlevel that exists when the push button is re-leased will be maintained.

f. Increasing and decreasing the weld current out-put can go on indefinitely.

g. If the weld current output is decreased to thevalue programmed for final current, the pro-gram will enter final current and proceed topostflow.

h. If weld current never exceeds the programmedvalue for final current, the weld current must bemanually decreased to zero, at which time theprogram will begin postflow.

4. After postflow is timed out, the control unit returnsto the Ready condition and waits for the nextclosure of the Start/Increase push button. If Start/Increase is pressed during postflow, the programwill restart the weld sequence from the beginningwithout preflow timing.


F. Operation Procedures For Semi-Automatic 5Mode

1. When the unit is in the Ready condition (seeSection 7-1F), momentarily press Start/Increase(or equivalent Start push button) to begin pro-gram execution. The control unit will initiate thearc and execute the programmed sequence tothe programmed weld level. Press Start/Increaseto indicate the end of weld and the beginning offinal slope. Once final slope begins, the Start/In-crease push button no longer has any affect onprogram execution.



8-3. Gas Tungsten Arc Welding (GTAW) InThe Manual Mode




3. Connect a suitable Contactor/Amperage remotecontrol to the Remote 14 receptacle.


5. Place Mode Selector switch in Manual GTAW po-sition.








13. Enter the Ready condition (see Section 7-1F).The operator now has control of the welding pow-er source contactor via the remote contactorcontrol connected to the Remote 14 receptacle.

14. Start welding as follows:

a. Be sure the desired program is active before ex-ecuting a program. The active program isindicated in the applicable repeating display(see Section 7-1F). To select a different pro-gram, press Parameter Select while therepeating displays are shown. This will increasethe program number.

b. Use the remote contactor control to energizethe welding power source contactor. This willinitiate preflow.

c. If high frequency is enabled, a high-frequencyarc initiation at the defined start current levelcan be performed after preflow.

If high frequency is disabled, a touch or scratchstart at the defined initial current level can beperformed after preflow.

15. While welding, the control unit will display theweld voltage and amperage values.

16. Weld output can be varied with the remote am-perage control. If pulsing is programmed On, the

OM-2803 Page 47

remote amperage control can increase the weld/peak and background current levels up to theprogrammed maximum values. The remote am-perage control can decrease the weld/peak andbackground current levels down to the definedinitial current level.

If pulsing is programmed Off, the remote amper-age control can increase the weld current up tothe programmed maximum weld level. The re-mote amperage control can decrease the weldcurrent down to the defined initial current level.

17. To stop welding, use the remote contactor controlto deenergize the welding power source contac-tor. Postflow will be carried out.

18. After postflow is timed out, the control unit returnsto the Ready condition. The operator must usethe remote contactor control to energize thewelding power source contactor to start weldingagain. If the welding power source contactor isenergized during postflow, the program will re-start the weld sequence from the beginningwithout preflow timing.

8-4. Shielded Metal Arc Welding (SMAW)





4. Connect a Finger Tip Control or Remote FootControl to the Remote 14 receptacle.

5. Place Mode Selector switch in SMAW position.



8. Select proper electrode.

9. Insert electrode into electrode holder.



12. Enter the Ready condition (see Section 7-1F).

13. Begin welding, observing the following:

a. Be sure the desired program is active before ex-ecuting a program. The active program isindicated in the applicable repeating display(see Section 7-1F). To select a different pro-gram, press Parameter Select while therepeating displays are shown. This will increasethe program number.

b. A closure of the remote contactor control con-tacts turns on the welding power source

contactor. The control unit waits for an arc to beinitiated with the stick electrode.

c. If Remote is enabled in the program (see Sec-tion 7-5), the remote control can be used toincrease the weld current up to the pro-grammed maximum weld level. The remoteamperage control can decrease the weld cur-rent down to the minimum current level thewelding power source can provide.

d. If Remote is disabled in the program, the con-trol unit will set the weld output to theprogrammed weld level value.

e. Opening the remote contacts turns off the weld-ing power source contactor.

f. While welding, the control unit will display theweld voltage and amperage values.

8-5. Executing Linked Programs1. Follow the Sequence Of Operation steps for the

applicable mode (Automatic, Semi-Automatic 1,or Semi-Automatic 5) until the Ready condition isentered.

2. When the repeating displays are shown, pressParameter Select until the program number in-creases beyond 4. The Link mode will be active.

3. Be sure the Link position to be executed first isthe first one in the Link Position displays.

4. Press Start/Increase on the Remote Pendant tobegin linked program execution.

8-6. Executing Combined Programs1. Follow the Sequence Of Operation steps for the

applicable mode (Automatic, Semi-Automatic 1,or Semi-Automatic 5) until the Ready condition isentered.

2. When the repeating displays are shown, pressParameter Select until the program number in-creases beyond 4. The Link mode will be active.

3. Press Parameter Select again to enter the Com-bine mode.

4. Press Start/Increase on the Remote Pendant tobegin combined program execution.

8-7. Shutting Down1. Stop welding.

2. Turn off welding power source and control unit.

3. Turn off shielding gas supply at the source, ifapplicable.

WARNINGBUILDUP OF SHIELDING GAS canharm health or kill.• Shut off shielding gas supply when not in use.

warn1.1 9/91

OM-2803 Page 48

SECTION 9 – DIAGNOSTICS

9-1. Introduction

A. General

The diagnostics program allows the following proce-dures to be carried out:

1. Testing the internal RAM memory

2. Testing the front panel programming pushbuttons

3. Testing the Run and Program positions of theProgram/Run/Reset key switch

4. Testing the mode selector switch

5. Testing the purge push button

6. Testing the digital to analog converter

7. Testing the analog to digital converter

8. Testing the output contactor relay

9. Testing the gas solenoid relay

10. Testing the arc starter relay

11. Testing user relay 1

12. Testing user relay 2

13. Testing the Remote Pendant

14. Testing the open circuit voltage detection circuitry

15. Testing the input contactor detection circuitry

16. Testing for the presence of the +10 volt dc inputreference signal at Remote 14 receptacle RC3

17. Calibrating the voltmeter

18. Calibrating the ammeter.

The RAM test and the programming push button testsare carried out each time the diagnostics program isstarted. The remaining tests can be performed in se-quence, or the Right/Increase or Left/Decrease pushbuttons can be used to access a desired test. Readthrough a test and gather needed equipment (if any)before following the procedure.

B. Running The Diagnostics Program

To carry out the diagnostics program, proceed as fol-lows:

1. Follow the directions in Section 3-2 for choosingthe diagnostics program on DIP switch SW1.

2. Place Program/Run/Reset key switch in Runposition.

3. Energize the unit.

C. Stopping The Diagnostics Program

To stop the diagnostics program, follow the directions inSection 3-2 for choosing program execution on DIPswitch SW1.

9-2. Diagnostics Program

When the diagnostics program starts, the followinginformational displays are shown:

* I N T E L L I T I G – 4 *

D I A G N O S T I C P R O G R A M

T H E F O L L O W I N G

P R O G R A M W I L L C H E C K

Y O U R U N I T T O V E R I F Y

T H A T I T I S

F U N C T I O N I N G

P R O P E R L Y

A. RAM Test

This procedure tests the internal RAM (random accessmemory) of the control unit to make sure each memorylocation is working properly.

1. After the four informational displays, the diagnos-tics program automatically tests the condition ofthe RAM memory. If the RAM tests okay, the dis-plays shows:

R A M I S W O R K I N G

P R O P E R L Y

If the RAM tests okay, proceed to Step 3.

2. If the RAM does not test okay, the following dis-plays appear:

E R R O R ! ! ! R A M I S

N O T W O R K I N G P R O P E R L Y

P L E A S E R E P L A C E R A M

B E F O R E C O N T I N U I N G

W I T H T H E D I A G N O S T I C

T E S T P R O G R A M

OM-2803 Page 49

If the RAM does not test okay, contact the near-est Factory Authorized Service Station/ServiceDistributor.

3. When the RAM tests okay, the diagnostics pro-gram proceeds to the next test.

B. Programming Push Button Tests

This procedure tests the operation of the individual frontpanel programming push buttons.

1. After the RAM test is passed, the diagnostics pro-gram proceeds to the test for the programmingpush buttons. The display shows:

P L E A S E P U S H

R I G H T / I N C B U T T O N

2. When this display appears, the control unit waitsnine seconds for the Right/Increase push buttonto be pressed. If this is done within the time al-lowed and the push button is working properly,the display shows:

R I G H T / I N C B U T T O N I S

W O R K I N G P R O P E R L Y

If the Right/Increase push button tests okay, pro-ceed to Step 4.

3. If the Right/Increase push button is not pressedwithin the time allowed, or if the push button is notworking correctly, the following displays appear:

E R R O R R I G H T B U T T O N

I S N O T W O R K I N G

P L E A S E C O R R E C T E R R O R




If the Right/Increase push button is not workingcorrectly, have Factory Authorized ServiceStation/Service Distributor check switch boardPC6 and microprocessor board PC1.

4. When the Right/Increase push button tests okay,the diagnostics program tests the Left/Decreasepush button. The display shows:

P L E A S E P U S H

L E F T / D E C B U T T O N

5. When this display appears, the control unit waitsnine seconds for the Left/Decrease push buttonto be pressed. If this is done within the time al-lowed and the push button is working correctly,the display shows:

L E F T / D E C B U T T O N I S


If the Left/Decrease push button tests okay, pro-ceed to Step 7.

6. If the Left/Decrease push button is not pressedwithin the time allowed, or if the push button is notworking correctly, the following displays appear:

E R R O R L E F T B U T T O N






If the Left/Decrease push button is not workingcorrectly, have Factory Authorized ServiceStation/Service Distributor check switch boardPC6 and microprocessor board PC1.

7. When the Left/Decrease push button tests okay,the diagnostics program tests the Parameter Se-lect push button. The display shows:

P L E A S E P U S H

P A R A M E T E R S E L E C T

8. When this display appears, the control unit waitsnine seconds for the Parameter Select push but-ton to be pressed. If this is done within the timeallowed and the push button is working correctly,the display shows:


I S W O R K I N G P R O P E R L Y

If the Parameter Select push button tests okay,proceed to Step 10.

OM-2803 Page 50

9. If the Parameter Select push button is notpressed within the time allowed, or if the pushbutton is not working correctly, the following dis-plays appear:

E R R O R P A R A M E T E R

S E L E C T N O T W O R K I N G





If the Parameter Select push button is not work-ing correctly, have Factory Authorized ServiceStation/Service Distributor check switch boardPC6 and microprocessor board PC1.

10. When the Parameter Select push button testsokay, the diagnostics program enters the user-selected test displays (see Section 9-2C).

C. User-Selected Test Displays

1. When the RAM memory and programming pushbuttons test okay, the diagnostics program entersthe user-selected test displays. This is a series offour repeating informational displays that appearas follows:

* I N T E L L I T I G – 4 *

D I A G N O S T I C P R O G R A M

U S E R I G H T / I N C O R

L E F T / D E C T O S E L E C T

T H E F U N C T I O N

T O T E S T

P A R A M E T E R S E L E C T T O

B E G I N / E N D T H E T E S T

2. The remaining diagnostic tests can be accessedfrom these displays. This is done by pressingeither the Right/Increase push button, or the Left/Decrease push button. The tests are presented

in the following subsections in the order theywould follow if the Right/Increase push buttonwere repeatedly pressed. The Left/Decreasepush button may also be used to access tests.

When a test is accessed and the ParameterSelect push button is not pressed to begin thetest, the diagnostics program will repeat the user-selected test displays.

D. Program/Run/Reset Key Switch Tests

This procedure tests the operation of the Run and Pro-gram positions of the Program/Run/Reset key switch.

1. When the user-selected test displays are shown(see Section 9-2C), press Right/Increase once.The display shows:

K E Y E D S W I T C H

T E S T

2. Press Parameter Select to begin the test. Thedisplay shows:

P L E A S E P U T K E Y I N

R U N P O S I T I O N

3. When this display appears, the control unit waitsthree seconds for the key switch to be placed inthe Run position. If this is done within the time al-lowed and the position is working correctly, thedisplay shows:

R U N P O S I T I O N


If the Run position tests okay, proceed to Step 5.

4. If the key switch is not placed in the Run positionwithin the time allowed, or if the position is notworking correctly, the display shows:

E R R O R ! ! R U N P O S I T I O N


If the Run position is not working correctly, re-place the key switch.

5. When the Run position tests okay, press Param-eter Select. The display shows:

P L E A S E P U T K E Y I N

P R O G R A M P O S I T I O N

OM-2803 Page 51

6. When this display appears, the control unit waitsthree seconds for the key switch to be placed inthe Program position. If this is done within thetime allowed and the position is working correctly,the display shows:

P R O G R A M P O S I T I O N


If the Program position tests okay, proceed toStep 8.

7. If the key switch is not placed in the Program po-sition within the time allowed, or if the position isnot working correctly, the display shows:

E R R O R ! ! P R O G R A M


If the Program position is not working correctly,replace the key switch.

8. When the Program position tests okay, pressParameter Select to exit the key switch tests. Usethe Right/Increase or Left/Decrease push but-tons to access another test, or stop thediagnostics program.

E. Mode Selector Switch Test

This procedure tests the operation of the four positionsof the Mode Selector switch.

1. When the user-selected test displays are shown(see Section 9-2C), press Right/Increase or Left/Decrease until the display shows:

M O D E S W I T C H

T E S T


P L E A S E T U R N K N O B T O

S M A W–MA N U A L P O S I T I O N

3. When this display appears, the control unit waitsthree seconds for the Mode Selector switch to beplaced in the SMAW position. If this is done withinthe time allowed and the position is working cor-rectly, the display shows:

S M A W – M A N U A L P O S I T I O N


If the SMAW position tests okay, proceed to Step5.

4. If the Mode Selector switch is not placed in theSMAW position within the time allowed, or if theposition is not working correctly, the displayshows:

E R R O R ! ! S M A W – M A N U A L


If the SMAW position is not working correctly,replace the Mode Selector switch.

5. When the SMAW position tests okay, pressParameter Select. The display shows:


G T A W – M A N U A L P O S I T I O N

6. When this display appears, the control unit waitsthree seconds for the Mode Selector switch to beplaced in the Manual GTAW position. If this isdone within the time allowed and the position isworking correctly, the display shows:

G T A W – M A N U A L P O S I T I O N


If the Manual GTAW position tests okay, proceedto Step 8.

7. If the Mode Selector switch is not placed in theManual GTAW position within the time allowed,or if the position is not working correctly, the dis-play shows:

E R R O R ! G T A W M A N U A L


If the Manual GTAW position is not working cor-rectly, replace the Mode Selector switch.

8. When the Manual GTAW position tests okay,press Parameter Select. The display shows:


G T A W S E M I – A U T O

9. When this display appears, the control unit waitsthree seconds for the Mode Selector switch to beplaced in the Semi-Automatic position. If this isdone within the time allowed and the position isworking correctly, the display shows:

S E M I – A U T O P O S I T I O N


If the Semi-Automatic position tests okay, pro-ceed to Step 11.

OM-2803 Page 52

10. If the Mode Selector switch is not placed in theSemi-Automatic position within the time allowed,or if the position is not working correctly, the dis-play shows:

E R R O R ! ! S E M I – A U T O


If the Semi-Automatic position is not working cor-rectly, replace the Mode Selector switch.

11. When the Semi-Automatic position tests okay,press Parameter Select. The display shows:


G T A W – A U T O P O S I T I O N

12. When this display appears, the control unit waitsthree seconds for the Mode Selector switch to beplaced in the Automatic position. If this is donewithin the time allowed and the position is workingcorrectly, the display shows:

G T A W – A U T O P O S I T I O N


If the Automatic position tests okay, proceed toStep 14.

13. If the Mode Selector switch is not placed in theAutomatic position within the time allowed, or ifthe position is not working correctly, the displayshows:

E R R O R ! ! G T A W A U T O


If the Automatic position is not working correctly,replace the Mode Selector switch.

14. When the Automatic position tests okay, pressParameter Select to exit the Mode Selectorswitch test (the Reset position is not tested). Usethe Right/Increase or Left/Decrease push but-tons to access another test, or stop thediagnostics program.

F. Purge Push Button Test

This procedure tests the operation of the purge pushbutton.


P U R G E B U T T O N

T E S T


P L E A S E P U S H

P U R G E B U T T O N

3. When this display appears, the control unit waitsthree seconds for the Purge push button to bepressed. If this is done within the time allowedand the push button is working correctly, the dis-play shows:

B U T T O N I S


If the Purge push button tests okay, proceed toStep 5.

4. If the Purge push button is not pressed within thetime allowed, or if the push button is not workingcorrectly, the display shows:

B U T T O N I S N O T


If the Purge push button is not working correctly,have Factory Authorized Service Station/ServiceDistributor check switch board PC6 and micro-processor board PC1.

5. When the Purge push button tests okay, pressParameter Select to exit the Purge push buttontest. Use the Right/Increase or Left/Decreasepush buttons to access another test, or stop thediagnostics program.

G. Digital To Analog Converter Test

This procedure tests the operation of the digital to ana-log converter. The control unit sends the converterdigital reference values and the expected analog valuesare then checked for in the test procedure.


D I G I T A L T O A N A L O G

C O N V E R T E R T E S T

OM-2803 Page 53


C H E C K R C 1 E ( + ) T O D

F O R + 1 0 V + / – . 0 5 V

3. Use a good quality digital multimeter (DMM) tocheck for +10 volts dc across pins E and D of ToPower Source receptacle RC1 on the rear of thecontrol unit.

4. If the expected value is found, proceed to Step 5.

If the expected value is not found, contact thenearest Factory Authorized Service Station/Service Distributor.

5. Press Parameter Select. The display shows:

C H E C K R C 1 E ( + ) T O D

F O R + 5 V + / – . 0 5 V

6. Use a good quality digital multimeter (DMM) tocheck for +5 volts dc across pins E and D of ToPower Source receptacle RC1 on the rear of thecontrol unit.

7. If the expected value is found, proceed to Step 8.


8. When the digital to analog converter tests okay,press Parameter Select to exit the test. Use theRight/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnosticsprogram.

H. Analog To Digital Converter Test

This procedure tests the operation of the analog to digi-tal converter. The control unit sends the converterpredetermined analog values and displayed digital val-ues are then compared to the expected values in thetest procedure.


A N A L O G T O D I G I T A L


2. Press Parameter Select to begin the test. A se-ries of displays will appear as follows:

W A R N I N G ! F O R B E S T

R E S U L T S P E R F O R M T H E

D I G I T A L T O A N A L O G


B E F O R E P E R F O R M I N G

T H I S T E S T

R I G H T / I N C T O

C O N T I N U E T H I S T E S T


T O R E T U R N T O M E N U

3. If the digital to analog converter has not beentested, do so at this time and return to the analogto digital test afterward. When the display aboveis shown, press Right/Increase. The displayshows:

D I S P L A Y = 4 0 9 5 + 0 – 2

X X X X X

4. The number represented by the X’s should equal4095 ± the specified range. If the expected valueis displayed, proceed to Step 5.


5. Press Parameter Select. The display shows:

D I S P L A Y = 2 0 4 8 + / – 4

X X X X X

6. The number represented by the X’s should equal2048 ± the specified range. If the expected valueis displayed, proceed to Step 7.

If the expected value is not displayed, contact thenearest Factory Authorized Service Station/Service Distributor.

7. When the analog to digital converter tests okay,press Parameter Select to exit the test. Use theRight/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnosticsprogram.

OM-2803 Page 54

I. Output Contactor Relay Test

This procedure allows the output contactor relay to bemanually energized to test its operation.


O U T P U T C O N T A C T O R

R E L A Y T E S T

2. Press Parameter Select to begin the test. Thisenergizes the output contactor relay. The displayshows:

C H E C K R C 1 P I N A T O B

F O R C O N T I N U I T Y

3. Use a good quality digital multimeter (DMM) tocheck for continuity across pins A and B on ToPower Source receptacle RC1 on the rear of thecontrol unit.

4. If continuity is found, proceed to Step 5.

If continuity is not found, contact the nearestFactory Authorized Service Station/ServiceDistributor.

5. When the output contactor relay tests okay,press Parameter Select to deenergize the outputcontactor relay and exit the test. Use the Right/In-crease or Left/Decrease push buttons to accessanother test, or stop the diagnostics program.

J. Gas Solenoid Relay Test

This procedure allows the gas solenoid relay to be man-ually energized to test its operation. Indirectly, the gassolenoid is also tested.


G A S S O L E N O I D

R E L A Y T E S T

2. Press Parameter Select to energize the gas sole-noid relay. The display shows:

G A S S O L E N O I D R E L A Y

I S E N E R G I Z E D

3. If gas flows, the gas solenoid relay and gas sole-noid are working correctly. In this case, proceedto Step 4.

If gas does not flow, contact the nearest FactoryAuthorized Service Station/Service Distributor.

4. When the gas solenoid relay tests okay, pressParameter Select again to deenergize the relay.The program automatically returns to the user-selected test displays. Use the Right/Increase orLeft/Decrease push buttons to access anothertest, or stop the diagnostics program.

K. Arc Starter Relay Test

This procedure allows the arc starter relay to be manual-ly energized to test its operation. Indirectly, the arcstarter board PC8 is also tested.


A R C S T A R T E R

R E L A Y T E S T

2. Press Parameter Select to energize the arc start-er relay. The display shows:

A R C S T A R T E R R E L A Y


3. If a crackling sound can be heard inside the con-trol unit, the relay is working correctly. In thiscase, proceed to Step 4.

If a crackling sound is not heard inside the controlunit, contact the nearest Factory AuthorizedService Station/Service Distributor.

4. When the arc starter relay tests okay, press Pa-rameter Select again to deenergize the relay. Theprogram automatically returns to the user-se-lected test displays. Use the Right/Increase orLeft/Decrease push buttons to access anothertest, or stop the diagnostics program.

L. User Relay #1 Test

This procedure allows user relay #1 to be manually en-ergized to test its operation.


U S E R R E L A Y

# 1 T E S T

2. Press Parameter Select to energize user relay#1. The display shows:

U S E R R E L A Y # 1


3. If the relay is working correctly, it energizes andremains energized (as indicated by the event thatuser relay #1 is being used to control). In thiscase, proceed to Step 4.

OM-2803 Page 55

If user relay #1 does not energize, contact thenearest Factory Authorized Service Station/Service Distributor.

4. Press Parameter Select again to deenergize therelay. The program automatically returns to theuser-selected test displays. Use the Right/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnosticsprogram.

M. User Relay #2 Test

This procedure allows user relay #2 to be manually en-ergized to test its operation.


U S E R R E L A Y

# 2 T E S T

2. Press Parameter Select to energize user relay#2. The display shows:

U S E R R E L A Y # 2


3. If the relay is working correctly, it energizes andremains energized (as indicated by the event thatuser relay #2 is being used to control). In thiscase, proceed to Step 4.

If user relay #2 does not energize, contact thenearest Factory Authorized Service Station/Service Distributor.

4. Press Parameter Select again to deenergize therelay. The program automatically returns to theuser-selected test displays. Use the Right/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnosticsprogram.

N. Remote Pendant Test

This procedure tests the operation of the push buttonson the Remote Pendant.


R E M O T E P E N D A N T

T E S T


P U S H S T A R T / I N C

O N R E M O T E

3. When this display appears, the control unit waitsthree seconds for the Start/Increase push buttonto be pressed. If this is done within the time al-lowed and the push button is working correctly,the display shows:

B U T T O N I S


If the Start/Increase push button tests okay, pro-ceed to Step 5.

4. If the Start/Increase push button is not pressedwithin the time allowed, or if the push button is notworking correctly, the display shows:



If the Start/Increase push button is not workingcorrectly, replace the push button.

5. When the Start/Increase push button tests okay,press Parameter Select. The display shows:

P U S H D E C R E A S E B U T T O N

O N R E M O T E

6. When this display appears, the control unit waitsthree seconds for the Decrease push button to bepressed. If this done within the time allowed andthe push button is working correctly, the displayshows:

B U T T O N I S


If the Decrease push button tests okay, proceedto Step 8.

7. If the Decrease push button is not pressed withinthe time allowed, or if the Decrease push button isnot working correctly, the display shows:



If the Decrease push button is not working cor-rectly, replace the push button.

8. When the Decrease push button tests okay,press Parameter Select. The display shows:

OM-2803 Page 56

P U S H S T O P B U T T O N

O N R E M O T E

9. When this display appears, the control unit waitsthree seconds for the Stop push button to bepressed. If this is done within the time allowedand the push button is working correctly, the dis-play shows:

B U T T O N I S


If the Stop push button tests okay, proceed toStep 11.

10. If the Stop push button is not pressed within thetime allowed, or if the push button is not workingcorrectly, the display shows:



If the Stop push button is not working correctly,replace the push button.

11. When the Stop push button tests okay, press Pa-rameter Select to exit the Remote Pendant tests.Use the Right/Increase or Left/Decrease pushbuttons to access another test, or stop the diag-nostics program.

O. Open Circuit Voltage Test

This procedure tests the circuitry within the control unitthat detects open circuit voltage (OCV) from the weldingpower source.


O C V D E T E C T

T E S T


P U T 6 0 – 1 0 0 V O L T S O N

P O S . A N D N E G . S T U D S

3. When this display appears, the control unit waitsthree seconds for the specified voltage to beplaced across the positive and negative outputterminals of the welding power source. If this isdone within the time allowed and the OCV detec-

tion circuitry is working correctly, the displayshows:

O P E N C I R C U I T

V O L T A G E D E T E C T E D

If OCV tests okay, proceed to Step 5.4. If OCV is not sensed within the time allowed, the

display shows:

O P E N C I R C U I T V O L T A G E

I S N O T D E T E C T E D

If OCV does not test okay, contact the nearestFactory Authorized Service Station/ServiceDistributor.

5. When OCV tests okay, press Parameter Selectto exit the OCV detect test. Use the Right/In-crease or Left/Decrease push buttons to accessanother test, or stop the diagnostics program.

P. Input Contactor TestThis procedure tests the operation of the circuitry thatdetects an input contactor closure.


I N P U T C O N T A C T O R

T E S T


P R O V I D E A C L O S U R E

O N R C 3 P I N S A T O B

3. When this display appears, the control unit waitsthree seconds for the specified contact closure atRemote 14 receptacle RC3. If this is done withinthe time allowed and the solid state contactor isworking correctly, the display shows:

I N P U T C O N T A C T O R

I S D E T E C T E D

If the input contactor detection circuitry testsokay, proceed to Step 5.

4. If the input contactor closure is not carried outwithin the time allowed, or if the related circuitry isnot working correctly, the display shows:

I N P U T C O N T A C T O R I S

N O T D E T E C T E D

OM-2803 Page 57

If the input contactor circuitry is not working cor-rectly, contact the nearest Factory AuthorizedService Station/Service Distributor.

5. When input contactor closure tests okay, pressParameter Select to exit the test. Use the Right/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnosticsprogram.

Q. +10 Volt Input Reference Test

This procedure tests for the presence of the +10 volt dcinput reference signal that is needed across pins C andD of Remote 14 receptacle RC3.


+ 1 0 V I N P U T R E F E R E N C E

T E S T


C H E C K R C 3 C ( + ) T O D

F O R + 1 0 V + / – . 0 5 V

3. Use a good quality digital multimeter (DMM) tocheck for the +10 volt dc input reference signalacross pins C and D of Remote 14 receptacleRC3. If the specified voltage is present, proceedto Step 5.

4. If the +10 volt dc input reference is not found,contact the nearest Factory Authorized ServiceStation/Service Distributor.

5. When the +10 volt dc input reference tests okay,press Parameter Select to exit the test. Use theRight/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnosticsprogram.

R. Voltmeter Test/Calibration

This procedure allows the control unit voltmeter to becalibrated to a voltage placed across the Positive Inputand Negative Input plugs on the unit rear panel.


V O L T M E T E R

T E S T / C A L I B R A T I O N


P U T V O L T S O N S T U D S

N O T E P O L A R I T Y

3. Use an external voltage source to provide a refer-ence voltage across the control unit input plugs.The display will show:

V O L T S = X X . X

U S E I N C / D E C T O C A L

4. Press Right/Increase and/or Left/Decrease asneeded until the voltage value in the displaymatches the reference voltage level.

5. When the voltage levels match, press ParameterSelect to exit the test. Use the Right/Increase orLeft/Decrease push buttons to access anothertest, or stop the diagnostics program.

S. Ammeter Test/Calibration

This procedure allows the control unit ammeter to becalibrated in reference to the current flowing through thePositive Input plug on the unit rear panel.


A M M E T E R

T E S T / C A L I B R A T I O N


P U T A M P S O N S T U D S

N O T E P O L A R I T Y

3. Use an external amperage source to provide areference current to the control unit input plugs.The display will show:

A M P S = X X . X

U S E I N C / D E C T O C A L

4. Press Right/Increase and/or Left/Decrease asneeded until the amperage value in the displaymatches the reference amperage level.

5. When the amperage levels match, press Param-eter Select to exit the test. Use theRight/Increase or Left/Decrease push buttons toaccess another test, or stop the diagnostics pro-gram.

OM-2803 Page 58

SECTION 10 – ELECTRICAL DIAGRAMS

SA-132 263

Figure 10-1. Circuit Diagram For Remote Pendant

OM-2803 Page 59

SC-156 492

Figure 10-2. Circuit Diagram For Control Unit

OM-2803 Page 60

Figure 10-3. Wiring Diagram For Control Unit

OM-2803 Page 61

SD-156 128

OM-2803 Page 62

SECTION 11 – HIGH FREQUENCYmod6.1 5/94

WARNINGHIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,computers, and communications equipment.• Have only qualified person familiar with electronic equipment perform this installation.

• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

• If notified by the FCC about interference, stop using the equipment 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 shieldingas shown in Figure 11-3 to minimize the possibility of interference.

1 Gas Tungsten Arc Torch

2 High-Frequency Voltage

Used to help arc jump air gapbetween torch and workpiece and/or stabilize the arc.

3 Submerged Arc Welding Gun

4 Flux

5 High-Frequency Voltage

Used to help arc reach workpiecethrough flux granules.

S-0693

1

Gas Tungsten ArcWelding (GTAW)

Submerged ArcWelding (SAW)

2

3

4

5

Work Work

Figure 11-1. Welding Processes Requiring High Frequency

50 ft(15 m)

Weld Zone

S-0694

1 Sources Of DirectHigh-Frequency Radiation

High-frequency source (weldingpower source with built-in HF orseparate HF unit), weld cables,torch, work clamp, workpiece, andwork table.

2 Sources Of Conduction OfHigh Frequency

Input power cable, line disconnectdevice, and input supply wiring.

3 Sources Of Reradiation OfHigh Frequency

Ungrounded metal objects, lighting,wiring, water pipe and fixtures,external phone and power lines.

3

2

2

1

1

3

1

3

3

Figure 11-2. Sources Of High-Frequency Radiation From Incorrect Installation

OM-2803 Page 63

1 High-Frequency Source (Welder WithBuilt-In HF Or Separate HF Unit)

Ground metal machine case, work outputterminal, line disconnect device, inputsupply, and worktable.

2 Center Point Of Welding Zone

Midpoint between high-frequency sourceand welding torch.

3 Welding Zone

A circle 50 ft (15 m) from center point in alldirections.

4 Weld Output Cables

Keep cables short and close together.

5 Conduit Joint Bonding

Electrically join (bond) all conduit sectionsusing copper straps or braided wire. Groundconduit every 50 ft (15 m).

6 Water Pipe And Fixtures

Ground water pipe every 50 ft (15 m).

7 External Power Or Telephone Lines

Locate high-frequency source at least 50 ft(15 m) away from power and phone lines.

8 Metal Building Panel Bonding Methods

Bolt or weld building panels together, installcopper straps or braided wire across seams,and ground frame.

9 Grounding Rod

Consult the National Electrical Code forspecifications.

10 Windows And Doorways

Cover all windows and doorways withgrounded copper screen of not more than1/4 in (6.4 mm) mesh.

11 Overhead Door Track

Ground the track.

8

9

11

10

S-0695

1

2

3 50 ft(15 m)

Weld Zone

4

7

50 ft(15 m)

Metal Building

NonmetalBuilding

9

5

9

9

6

Ground AllMetal ObjectsAnd All Wiring

In Welding ZoneUsing #12 AWG Wire

GroundWorkpieceIf RequiredBy Codes

Figure 11-3. Correct Installation

OM-2803 Page 64

SECTION 12 – TUNGSTEN ELECTRODEmod2.1 1/94

For additional information, see your distributor for a handbook on the GasTungsten Arc Welding (GTAW) process.

Wear clean gloves to prevent contamination of tungsten electrode.

NOTE

12-1. Selecting Tungsten Electrode

Table 12-1. Tungsten Size

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC – Argon – ElectrodeNegative/Straight Polarity

DC – Argon – ElectrodePositive/Reverse Polarity

AC – Argon – UsingHigh Frequency

AC – Argon – BalancedWave Using High Freq.

Pure Tungsten(Green Band)

.010” Up to 15 * Up to 15 Up to 10

.020” 5-20 * 5-20 10-20

.040” 15-80 * 10-60 20-30

1/16” 70-150 10-20 50-100 30-80

3/32” 125-225 15-30 100-160 60-130

1/8” 225-360 25-40 150-210 100-180

5/32” 360-450 40-55 200-275 160-240

3/16” 450-720 55-80 250-350 190-300

1/4” 720-950 80-125 325-450 250-400

2% Thorium AlloyedTungsten (Red Band)

.010” Up to 25 * Up to 20 Up to 15

.020” 15-40 * 15-35 5-20

.040” 25-85 * 20-80 20-60

1/16” 50-160 10-20 50-150 60-120

3/32” 135-235 15-30 130-250 100-180

1/8” 250-400 25-40 225-360 160-250

5/32” 400-500 40-55 300-450 200-320

3/16” 500-750 55-80 400-500 290-390

1/4” 750-1000 80-125 600-800 340-525

Zirconium Alloyed Tung-sten (Brown Band)

.010” * * Up to 20 Up to 15

.020” * * 15-35 5-20

.040” * * 20-80 20-60

1/16” * * 50-150 60-120

3/32” * * 130-250 100-180

1/8” * * 225-360 160-250

5/32” * * 300-450 200-320

3/16” * * 400-550 290-390

1/4” * * 600-800 340-525

♦ Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).

*Not Recommended.

The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrodemanufacturers. S-0009

OM-2803 Page 65

12-2. Preparing Tungsten

1 Tungsten Electrode

2 Balled End

Ball end of tungsten before weldingby applying either an ac amperageslightly higher than what is recom-mended for a given electrode diam-eter (see Table 12-1), or a dc elec-trode positive amperage.

Ref. S-0161

1

1-1/2 Times

2

Electrode Diameter

Figure 12-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding

CAUTIONFLYING SPARKS AND HOT METAL can cause injury and start fires.• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

• Keep flammables away.warn2.1 9/91

1 Tungsten Electrode

2 Tapered End

Grind end of tungsten on fine grit,hard abrasive wheel before weld-ing. Do not use wheel for other jobsor tungsten can become contami-nated causing lower weld quality.

3

Ideal Tungsten Preparation – Stable Arc

Ref. S-0162

Ref. S-0161

2-1/2 TimesElectrode Diameter

1 2

1 Stable Arc

2 Flat

Diameter of this flat determinesamperage capacity.

3 Grinding Wheel

4 Straight Ground3

1

2

1 Arc Wander

2 Point

3 Grinding Wheel

4 Radial Ground2

1

4

Ref. S-0162

Wrong Tungsten Preparation – Wandering Arc

4

Figure 12-2. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

OM-2803 Page 66

SECTION 13 – PARTS LIST

Figure 13-1. Main Assembly

ST-146 844-A

12

3

45

6

7

8

9

10 11

1213

14

15

16

17 1819

20

2122

23

Fig

13-

3

Fig

13-

4

24

25

26

27

28

Fig

13-

2

30

29

31

32

33

� Hardware is common andnot available unless listed.

OM-2803 Page 67

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 13-1. Main Assembly

Quantity

1 ♦ 126 416 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 126 415 CLAMP, saddle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146 112 BLANK, snap-in nyl .218mtg hole 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 +142 478 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 T1 143 462 TRANSFORMER, control (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 131 052 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 TE1 038 081 BLOCK, term 20A 4P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 219 LINK, jumper term blk 20A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 FL1,2 084 171 FILTER, line pwr 115/250V 50-400Hz at 2A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 094 484 STAND-OFF, 6-32 x 1.000 lg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F1 *012 663 FUSE, mintr gl slo-blo 3A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 012 571 HOLDER, fuse mintr .250 x 1.250clp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PC3 150 896 CIRCUIT CARD, interface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG11 115 093 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG12 114 366 CONNECTOR, rect 13skt plug Amp 1-640440-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG14 115 092 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG15 115 094 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG16 119 490 CONNECTOR, rect 8skt plug Amp 640440-8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 142 480 PANEL, interface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 148 299 STRIP, insulating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 073 756 STAND-OFF, 6-32 x .625 lg 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 080 509 GROMMET, scr No. 8/10 panel hole .312sq .375 high 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 098 691 STAND-OFF, 6-32 x .500 lg 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 134 201 STAND-OFF SUPPORT, PC card .312/.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 142 479 PANEL, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PC4 142 281 POWER SUPPLY, switching 85-132VAC/110-170VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 PC8 151 248 KIT, circuit card arc starter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG22 165 884 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 748 CONNECTOR, rect skt 22-18ga JST SVH-21T-1.1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG23 146 099 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 748 CONNECTOR, rect skt 22-18ga JST SVH-21T-1.1 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 R1 136 076 RESISTOR, WW fxd 30W 200 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 T2 148 654 ARC STARTER, pulsed HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fig 13-3 PANEL, rear w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 132 064 PENDANT, (Fig 13-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 134 756 LABEL, warning electric shock can kill 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 +148 557 CASE SECTION, bottom/sides (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 197 NUT, insert .312-18 panel mtg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 091 772 STAND-OFF, 6-32 x .625 lg 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 142 501 MOUNT, sgl stud 1.500dia .312-18 stud 1.250 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fig 13-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PC1 185 230 CIRCUIT CARD, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 131 056 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 089 222 CONNECTOR, rect 11skt plug Amp 1-640440-1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG3,6 114 366 CONNECTOR, rect 13skt plug Amp 1-640440-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG4,5 119 490 CONNECTOR, rect 8skt plug Amp 640440-8 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 057 357 BUSHING, snap-in nyl .937 ID x 1.125mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 PC2 148 211 CIRCUIT CARD, filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7,8 119 490 CONNECTOR, rect 8skt plug Amp 640440-8 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG9,10 114 366 CONNECTOR, rect 13skt plug Amp 1-640440-3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 605 670 NUT, speed 12-24 screw 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


OM-2803 Page 68

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 13-1. Main Assembly (Continued)

Quantity


RC20 135 635 CONNECTOR & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 656 CONNECTOR, rect pin 24-18ga Molex 39-00-0040 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC21 115 090 CONNECTOR & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 656 CONNECTOR, rect pin 24-18ga Molex 39-00-0040 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-2803 Page 69

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 13-2. Panel, Front w/Components (Fig 13-1 Item 28)

Quantity

1 111 569 METER, flow 6-60CFH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 112 090 FITTING, pipe brs elbow 1/8NPT x 3/16 hose 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 142 167 SPACER, brs .218 ID x .437 OD x .100thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 142 166 BRACKET, mtg flow meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 010 855 RETAINER, screw No. 2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 073 756 STAND-OFF, 6-32 x .625 lg 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PC6 154 399 CIRCUIT CARD, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG18 089 241 CONNECTOR, rect 4skt plug Amp 640440-4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG19 089 222 CONNECTOR, rect 11skt plug Amp 1-640440-1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PC5 156 046 DISPLAY, LED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG17 156 045 CONNECTOR, rect 14skt plug Amp 1-640440-4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 142 172 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 142 170 PANEL, front lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 S2 125 945 SWITCH, key 3posn .750mtg hole .4VA 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 115 360 KNOB, arrow .125 shaft dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 115 359 CAP, peaked 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 089 186 ACTUATOR, switch 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 126 908 BEZEL/FILTER, blue filter non-glare 4 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 010 853 FASTENER, screw sltd hd No. 2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-146 944-A

1 2 3 4

5 6

7

8

9

10

111213

1415

16

17


Figure 13-2. Panel, Front w/Components

To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2803 Page 70

ST-146 843-C


12

3 4 5

6 7

8

9

11

12

13

14

15

16

17

18

19

20

21

4

10

10

Figure 13-3. Panel, Rear w/Components

OM-2803 Page 71

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 13-3. Panel, Rear w/Components (Fig 13-1 Item 22)

Quantity

1 RC1 152 492 CONNECTOR w/PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 731 CONNECTOR, circ pin push-in 14-18ga Amp 213603-1 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 426 CONNECTOR, circ 14skt plug Amp 213652-1. . . . . . . . . . . . . . . . . . . . . . . . . . . 079 534 CONNECTOR, circ skt push-in 14-18ga Amp 66358-6. . . . . . . . . . . . . . . . . . . . . . . . . . . 079 739 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or). . . . . . . . . . . . . . . . . . . . . . . . . . . 143 922 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

2 C4-7 128 692 CAPACITOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 RC2 073 687 CONNECTOR, circ 4skt rcpt Amphenol MS-3102A-14S-2S 1. . . . . . . . . . . . . . . . . . . . . . .

053 075 CONNECTOR, circ 4 pin plug Amphenol MS-3106A-14S-2P. . . . . . . . . . . . . . . . . . . . . . . . . . . 039 828 CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6. . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Neg,Pos Input 143 419 RECEPTACLE, twlk insul male (Dinse type) 50/70 series 2. . . . . . . . . . . . . . . . . 5 140 732 PLATE, rear panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 024 103 BLANK, snap-in nyl .750mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 S1 116 830 SWITCH, rocker DPST 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 605 227 NUT, nylon hex jam .750NPST 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 142 494 BUSHING, strain relief .090/.265 ID x .492mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Neg,Pos,Torch 185 703 RECEPTACLE, twlk insul fem (Dinse type) 50/70 series 3. . . . . . . . . . . . . . . . . . 11 142 168 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 RC3 143 976 CONNECTOR w/SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 534 CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 734 CONNECTOR, circ 14 pin plug Amp 213571-2. . . . . . . . . . . . . . . . . . . . . . . . . . . 134 731 CONNECTOR, circ pin push-in 14-18ga Amp 213603-1. . . . . . . . . . . . . . . . . . . . . . . . . . . 079 739 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or). . . . . . . . . . . . . . . . . . . . . . . . . . . 143 922 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3. . . . . . . . . . . . . . . . . . . . . . . . . . . 094 334 PROTECTIVE CAP, poly, size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 C2 143 416 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C1,3 135 286 CAPACITOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C8 143 406 LEAD ASSEMBLY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C9 143 408 LEAD ASSEMBLY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C10 143 410 LEAD ASSEMBLY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C11 143 412 LEAD ASSEMBLY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C12 143 414 LEAD ASSEMBLY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 129 381 BRACKET, mtg current transducer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 HD1 156 313 TRANSDUCER, current 300A module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG24 130 204 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 066 CONNECTOR, rect skt 20-14ga Amp 350536-1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 089 120 CLAMP, hose .375-.450clp dia slfttng 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 134 834 HOSE, SAE .187 ID x .410 OD (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 120 854 FITTING, gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 GS1 133 873 VALVE, 24VDC 2 way custom port 1/8 orf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117 860 BLANK, snap-in nyl .187mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 746 WRENCH, hex 5mm short 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


OM-2803 Page 72

DescriptionPartNo.

Dia.Mkgs.

132 064

ItemNo.

Figure 13-4. Pendant (Fig 13-1 Item 23)

Quantity

1 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 134 429 CASE SECTION, front/end 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 S1 079 724 SWITCH, PB MC SPDT 6A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 S2,3 021 105 SWITCH, PB Licon 76-2351 SPDT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 148 348 CASE SECTION, back/sides/end 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 134 900 STRAIN RELIEF, cable flexible .270-.480 cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 604 571 CABLE, port No. 18 4/c (order by ft) 15ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 039 828 CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6 1. . . . . . . . . . . . . . . . . . . . . . . . . . 9 PLG50 053 075 CONNECTOR, circ 4 pin plug Amphenol MS-3106A-14S-2P 1. . . . . . . . . . . . . . . . . . . . . . .

10 079 725 GUARD, switch al knurled 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-146 840-A

1

2

3

4

5

6

7

8

9

10

3


Figure 13-4. Pendant


OM-2803 Page 73

Notes

OM-2803 Page 74

Notes

Warranty Questions?

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

miller_warr 7/00

Your distributor also givesyou ...

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

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

Effective January 1, 2000(Equipment with a serial number preface of “LA” or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

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

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

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

1. 5 Years Parts – 3 Years Labor

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

2. 3 Years — Parts and Labor

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

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

3. 1 Year — Parts and Labor

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

185 & Spoolmate 250)* Process Controllers* Positioners and Controllers* Automatic Motion Devices* RFCS Foot Controls* Induction Heating Power Sources* Water Coolant Systems* HF Units* Grids* Maxstar 140* Spot Welders* Load Banks* Miller Cyclomatic Equipment* Running Gear/Trailers* Plasma Cutting Torches (except APT & SAF

Models)* Field Options

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

4. 6 Months — Batteries

5. 90 Days — Parts

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

* APT, ZIPCUT & PLAZCUT Model Plasma CuttingTorches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate 185 & Spoolmate 250

* Canvas Covers

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

1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, slip rings,relays or parts that fail due to normal wear.

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

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

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

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

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

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

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

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

PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00

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

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

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

www.MillerWelds.com

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

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

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Informationand Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier for:

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

For Service

Owner’s Record

File a claim for loss or damage duringshipment.

Contact your Distributor for:

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