OM-358

188 291B

December 1998

Processes
TIG (GTAW) Welding
Stick (SMAW) Welding

Description
230/460 Volt Models W/Autolink

400 Volt Models

Arc Welding Power Source

Dynasty 300 DX

And Non-CE Models

Visit our website at

www.MillerWelds.com

From Miller to You

Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you dont have time to do it any other way.
Thats why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. Weve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, theres a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered
you may need to fix the problem. Warranty and
to the ISO 9001 Quality
service information for your particular model
System Standard.
are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.

Working as hard as you

do every power source
from Miller is backed by
the most hassle-free warranty in the business.

Miller offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.

TABLE OF CONTENTS

WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)

The following terms are

used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW

OM-358B

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance
1-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturers Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. 115 Volts AC Duplex Receptacle, Circuit Breaker CB1 (Optional), And Power Switch . . . . .
3-6. Weld Output Terminals and Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote Program Select Inputs (Optional For Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11.Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Description Of Controls (Use With Sections A And B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Remote Trigger (Normal) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Remote Trigger (2T) Hold Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. 4T (Specific Trigger Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Reconfiguring 4T For Mini Logic Control, Spot, Or Contactor On Lift-Arc . . . . . . . . . . . . . . . .
4-7. Mini Logic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Spot Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Contactor On Lift-Arc Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10.Lift-Arct And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11.Programmable HF Start Amperage And Time Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12.Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13.Lock Out Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY

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Declaration of Conformity For

European Community (CE) Products
NOTE

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

Miller Electric Mfg. Co.

Manufacturers Name:

1635 W. Spencer Street

Appleton, WI 54914 USA

Manufacturers Address:

Declares that the product:

Dynastyt 300 DX

conforms to the following Directives and Standards:

Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(December 1996 Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995

European Contact:

Telephone:
Fax:
dec_con1 10/95

Mr. Luigi Vacchini, Managing Director

MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section NO TAG. Read and follow all Safety Standards.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable do not use work clamp or work cable.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

Y During operation, keep everybody, especially children, away.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.

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

D Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first double-check connections.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not drape cables over your body.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

OM-358 Page 1

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.

OM-358 Page 2

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

1-3. Additional Symbols for Installation, Operation, and Maintenance

FIRE OR EXPLOSION hazard.

MOVING PARTS can cause injury.

D Do not install or place unit on, over, or near

combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards
closed and securely in place.

FALLING UNIT can cause injury.

H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.

D
D

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.
D Have only qualified persons 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 shielding to
minimize the possibility of interference.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.

ARC WELDING can cause interference.

MOVING PARTS can cause injury.

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

D
D

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.

D
D

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection 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, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-358 Page 3

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

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

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

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

To reduce magnetic fields in the workplace, use the following

procedures:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

OM-358 Page 4

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

4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:

SECTION 1 CONSIGNES DE SECURITE

LIRE AVANT UTILISATION

som _nd_Fre 4/97

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdure
prsente des risques de danger ! Ceux-ci sont identifis
par des symboles adjacents aux directives.

Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

risques de danger relis aux CHOCS LECTRIQUES, aux PICES EN
MOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connatre les mesures prendre pour
viter tout danger.

1-2. Dangers relatifs au soudage larc

Y Les symboles prsents ci-aprs sont utiliss tout au long du
prsent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnes afin dviter tout danger. Les
consignes de scurit prsentes ci-aprs ne font que rsumer
linformation contenue dans les normes de scurit numres
la section 1-5. Veuillez lire et respecter toutes ces normes de
scurit.

D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-lechamp les pices endommages. Entretenir lappareil conformment
ce manuel.
D Porter un harnais de scurit quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.

Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies.

D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal

avec la pice souder ou la table de travail, le plus prs possible de la
soudure.

Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.

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

UN CHOC LECTRIQUE peut tuer.

Un simple contact avec des pices lectriques peut
provoquer une lectrocution ou des blessures graves.
Llectrode et le circuit de soudage sont sous tension
ds que lappareil est sur ON. Le circuit dentre et les
circuits internes de lappareil sont galement sous
tension ce moment-l. En soudage semi-automatique ou automatique,
le fil, le dvidoir, le logement des galets dentranement et les pices
mtalliques en contact avec le fil de soudage sont sous tension. Des
matriels mal installs ou mal mis la terre prsentent un danger.

Il y a DU COURANT CONTINU IMPORTANT dans les

convertisseurs aprs la suppression de lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique, et dcharger les condensateurs dalimentation selon les instructions
indiques dans la partie entretien avant de toucher les pices.

D Ne jamais toucher les pices lectriques sous tension.

D Porter des gants et des vtements de protection secs ne comportant
pas de trous.
D Sisoler de la pice et de la terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empcher le contact physique ventuel avec la pice ou la terre.
D
D
D

Ne pas se servir de source lectrique courant lectrique dans les zones

humides, dans les endroits confins ou l o on risque de tomber.
Se servir dune source lectrique courant lectrique UNIQUEMENT si le
procd de soudage le demande.
Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.

D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
scurit).
D Installer et mettre la terre correctement cet appareil conformment
son manuel dutilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la
borne de terre du sectionneur ou que la fiche du cordon est raccorde
une prise correctement mise la terre.
D En effectuant les raccordements dentre fixer dabord le conducteur
de mise la terre appropri et contre-vrifier les connexions.
D Vrifier frquemment le cordon dalimentation pour voir sil nest pas
endommag ou dnud remplacer le cordon immdiatement sil est
endommag un cble dnud peut provoquer une lectrocution.
D Mettre lappareil hors tension quand on ne lutilise pas.
D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss.
D Ne pas enrouler les cbles autour du corps.
D Si la pice soude doit tre mise la terre, le faire directement avec un
cble distinct ne pas utiliser le connecteur de pice ou le cble de
retour.
D Ne pas toucher llectrode quand on est en contact avec la pice, la
terre ou une lectrode provenant dune autre machine.

LES FUMES ET LES GAZ peuvent

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

D
D
D
D

D Eloigner votre tte des fumes. Ne pas respirer

les fumes.
A lintrieur, ventiler la zone et/ou utiliser un chappement au niveau
de larc pour lvacuation des fumes et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur alimentation dair homologu.
Lire les spcifications de scurit des matriaux (MSDSs) et les
instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs.
Travailler dans un espace ferm seulement sil est bien ventil ou en
portant un respirateur alimentation dair. Demander toujours un
surveillant dment form de se tenir proximit. Des fumes et des
gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger.
Ne pas souder dans des endroits situs proximit doprations de
dgraissage, de nettoyage ou de pulvrisation. La chaleur et les
rayons de larc peuvent ragir en prsence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des mtaux munis dun revtement, tels que lacier
galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien
ventil, et si ncessaire, en portant un respirateur alimentation
dair. Les revtements et tous les mtaux renfermant ces lments
peuvent dgager des fumes toxiques en cas de soudage.

OM-358 Page 5

LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et
sur la peau.
Le rayonnement de larc du procd de soudage
gnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brlures dans les yeux et sur la peau. Des tincelles sont projetes
pendant le soudage.

D Porter un casque de soudage muni dun cran de filtre appropri pour

protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).
D Porter des protections approuvs pour les oreilles si le niveau sondre est
trop lev.

D Utiliser des crans ou des barrires pour protger des tiers de lclair
et de lblouissement; demander aux autres personnes de ne pas regarder larc.
D Porter des vtements de protection constitu dans une matire durable, rsistant au feu (cuir ou laine) et une protection des pieds.

LE SOUDAGE peut provoquer un

incendie ou une explosion.
Le soudage effectu sur des conteneurs ferms tels
que des rservoirs, tambours ou des conduites peut
provoquer leur clatement. Des tincelles peuvent tre
projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peut provoquer des
incendies et des brlures. Le contact accidentel de llectrode avec des
objets mtalliques peut provoquer des tincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vrifier
et sassurer que lendroit ne prsente pas de danger.
D Se protger et dautres personnes de la projection dtincelles et de
mtal chaud.
D Ne pas souder dans un endroit l o des tincelles peuvent tomber sur
des substances inflammables.
D Dplacer toutes les substances inflammables une distance de 10,7
m de larc de soudage. En cas dimpossibilit les recouvrir soigneusement avec des protections homologus.
D Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.
D Le soudage effectu sur un plafond, plancher, paroi ou sparation
peut dclencher un incendie de lautre ct.
D Ne pas effectuer le soudage sur des conteneurs ferms tels que des
rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de
scurit).
D Brancher le cble sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par
des chemins inconnus ventuels en provoquant des risques dlectrocution et dincendie.
D Ne pas utiliser le poste de soudage pour dgeler des conduites geles.
D En cas de non utilisation, enlever la baguette dlectrode du portelectrode ou couper le fil la pointe de contact.
D Porter des vtements de protection dpourvus dhuile tels que des
gants en cuir, une chemise en matriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTES

peuvent blesser les yeux.
D Le soudage, lcaillement, le passage de la pice
la brosse en fil de fer, et le meulage gnrent
des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier.
D

Porter des lunettes de scurit avec crans latraux ou un cran facial.

OM-358 Page 6

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou

mme la mort.
D

Fermer lalimentation du gaz protecteur en cas de

non utilisation.
Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu.

DES PICES CHAUDES peuvent provoquer des brlures graves.

D Ne pas toucher des parties chaudes mains nues
D Prvoir une priode de refroidissement avant
dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.
D
D

Porteurs de stimulateur cardiaque, restez distance.

Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher
des oprations de soudage larc, de gougeage ou
de soudage par points.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecter
loue.
D

Porter des protections approuvs pour les oreilles si

le niveau sondre est trop lev.

Si des BOUTEILLES sont endommages, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommage, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procd de soudage, les
manipuler avec prcaution.
D Protger les bouteilles de gaz comprim dune chaleur excessive,
des chocs mcaniques, du laitier, des flammes ouvertes, des tincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de
se renverser.
D Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques.
D Ne jamais placer une torche de soudage sur une bouteille gaz.
D Une lectrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressurise risque dexplosion.
D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,
tuyaux et raccords convenables pour cette application spcifique;
les maintenir ainsi que les lments associs en bon tat.
D Ne pas tenir la tte en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publications P-1 CGA numres dans les normes de scurit.

1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance
Risque DINCENDIE OU
DEXPLOSION.

DES ORGANES MOBILES peuvent

provoquer des blessures.

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

D Rester lcart des organes mobiles comme le

ventilateur.
D Maintenir ferms et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.

D Ne pas installer lappareil proximit de produits inflammables

D Ne pas surcharger linstallation lectrique sassurer que lalimentation est correctement dimensionn et protg avant de mettre
lappareil en service.

LE RAYONNEMENT HAUTE FRQUENCE (H.F.) risque de provoquer

des interfrences.

LA CHUTE DE LAPPAREIL peut

blesser.
D Utiliser lanneau de levage uniquement pour soulever lappareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin dune capacit approprie pour
soulever lappareil.
D En utilisant des fourches de levage pour dplacer lunit, sassurer
que les fourches sont suffisamment longues pour dpasser du ct
oppos de lappareil.

LEMPLOI EXCESSIF peut

SURCHAUFFER LQUIPEMENT.

D
D
D
D
D

D Prvoir une priode de refroidissement, respecter le cycle opratoire nominal.

D Rduire le courant ou le cycle opratoire avant de
recommancer le soudage.

LE SOUDAGE LARC risque de

provoquer des interfrences.

D Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pices.
D Utiliser des pochettes et des botes antistatiques
pour stocker, dplacer ou expdier des cartes de
circuits imprimes.

DES ORGANES MOBILES peuvent

provoquer des blessures.
D Ne pas sapprocher des organes mobiles.
D Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gachette avant den avoir
reu linstruction.
D Ne pas diriger le pistolet vers soi, dautres personnes ou toute pice mcanique en engageant le fil
de soudage.

D Le rayonnement haute frequence peut provoquer

des interfrences avec les quipements de radionavigation et de communication, les services
de scurit et les ordinateurs.
Demander seulement des personnes qualifies familiarises
avec des quipements lectroniques de faire fonctionner linstallation.
Lutilisateur est tenu de faire corriger rapidement par un lectricien
qualifi les interfrences rsultant de linstallation.
Si le FCC signale des interfrences, arrter immdiatement lappareil.
Effectuer rgulirement le contrle et lentretien de linstallation.
Maintenir soigneusement ferms les portes et les panneaux des
sources de haute frquence, maintenir les clateurs une distance
correcte et utiliser une terre et et un blindage pour rduire les interfrences ventuelles.

D
D
D
D
D

D Lnergie lectromagntique risque de provoquer

des interfrences pour lquipement lectronique
sensible tel que les ordinateurs et lquipement
command par ordinateur tel que les robots.
Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement.
Pour rduire la possibilit dinterfrence, maintenir les cbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller souder une distance de 100 mtres de tout quipement
lectronique sensible.
Veiller ce que ce poste de soudage soit pos et mis la terre
conformment ce mode demploi.
En cas dinterfrences aprs avoir pris les mesures prcdentes, il
incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.

LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez distance.
D Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.

OM-358 Page 7

1-4. Principales normes de scurit

Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Rgles de scurit en soudage, coupage et procds connexes, norme
CSA W117.2, de lAssociation canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs lectromagntiques

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

Afin de rduire les champs lectromagntiques dans lenvironnement

de travail, respecter les consignes suivantes :

Lextrait suivant est tir des conclusions gnrales du document intitul

Biological Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTABPE53 (Washington DC : U.S. Government Printing Office, mai 1989), publi par le Office of Technology
Assessment du Congrs amricain : ... il existe maintenant dabondantes donnes scientifiques compiles la suite dexpriences sur la
cellule ou dtudes sur des animaux et des humains, qui montrent clairement que les champs lectromagntiques basse frquence peuvent
avoir des effets sur lorganisme et mme y produire des transformations. Mme sil sagit de travaux de trs grande qualit, les rsultats
sont complexes. Cette dmarche scientifique ne nous permet pas
dtablir un tableau densemble cohrent. Pire encore, elle ne nous permet pas de tirer des conclusions finales concernant les risques
ventuels, ni doffrir des conseils sur les mesures prendre pour rduire sinon liminer les risques ventuels. (Traduction libre)

OM-358 Page 8

2
3
4
5

Garder les cbles ensembles en les torsadant ou en les

attachant avec du ruban adhsif.
Mettre tous les cbles du ct oppos de loprateur.
Ne pas courber pas et ne pas entourer pas les cbles autour de
vous.
Garder le poste de soudage et les cbles le plus loin possible de
vous.
Relier la pince de masse le plus prs possible de la zone de
soudure.

Consignes relatives aux stimulateurs cardiaques :

Les consignes mentionnes prcdemment font partie de celles destines aux personnes ayant recours un stimulateur cardiaque. Veuillez
consulter votre mdecin pour obtenir plus de dtails.

SECTION 2 DEFINITIONS (CE Models)

2-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1

1.2

1.3

2
1

1.1

1.2

1.3
2.1
2.2
2.3

2.1

2.2

2.3
3
3.1

3.1

3.2

3.2

3.3

3.3
4

4.1

+
5

4.1

6
S-179 310

Electric shock from welding

electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.

1/96

OM-358 Page 9

Warning! Watch Out! There are

possible hazards as shown by the
symbols.
1
2
1

V
V
> 60 s

6
S-185 836

7
6

1
1
2
3

= <60

Electric shock from wiring can

kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 60 seconds after
power is turned off before
working on unit, OR
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.

Warning! Watch Out! There

are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.

S-179 309-A

5
1/96

OM-358 Page 10

2-2. Manufacturers Rating Label For CE Products

. For label location
see Section 3-4.

ST-189 968-A

OM-358 Page 11

2-3. Symbols And Definitions

Amperes

PanelLocal

Volts

Input

Output

Circuit Breaker

Remote

Protective Earth
(Ground)

Postflow Timer

Preflow Timer

On

Off

Positive

Alternating
Current

Gas Input

Gas Output

Duty Cycle

Direct Current

Line Connection

X
U1
U0

Primary Voltage

IP

Degree Of
Protection

Gas Tungsten Arc

Welding (GTAW)

Shielded Metal Arc

Welding (SMAW)

3 Phase Static Frequency

Converter-Transformer-Rectifier

I1max

Rated Maximum
Supply Current

Touch Start
(GTAW)

Seconds

Negative

I2

Rated Welding
Current

U2

Conventional Load
Voltage

I1eff

Maximum Effective
Supply Current

Rated No Load
Voltage (Average)

Pulse Background
Amperage

Initial Amperage

Increase/Decrease
Of Quantity

Normal Trigger Operation (GTAW)

Two-Step Trigger
Operation (GTAW)

Four-Step Trigger
Operation (GTAW)

Percent

Hertz

Recall From
Memory

Arc Force (DIG)

Impulse Starting
(GTAW)

Final Slope

Final Amperage

Pulse Percent
On Time

Initial Slope

Contactor Control
(Stick)

Pulser On-Off

TIG Weld Amps

And Peak Amps
While Pulsing

Pulse Frequency

Work

Electrode

Balance % EN
Time (AC GTAW)

Hz

Unit may be used

in environments
with increased
hazard of electric
shock

OM-358 Page 12

SECTION 3 INSTALLATION
3-1. Specifications
A. For Multivoltage Units

Input Power

Rated Welding Output

Amperage
Range

Maximum
Open-Circuit
Voltage DC

250 A @ 30 Volts AC, 40%

Duty Cycle
Three Phase

200 A @ 28 Volts DC, 40%

Duty Cycle

5300

95

250 A @ 30 Volts AC, 40%

Duty Cycle
Single Phase

5300

95

200 A @ 28 Volts DC, 40%

Duty Cycle

Amperes Input at Rated Load Output 60 Hz

230 V

460 V

KVA

KW

26.3
*.27

17.9
*.15

14.2
*.09

10.5
*.04

20.5
*.27

13.4
*.15

8.4
*.09

7.6
*.04

62.6
*.33

32.2
*.18

14.8
*.10

10.4
*.07

44
*.33

25.8
*.18

11.9
*.1

8.1
*.07

*While idling

B. For Single Voltage Units

Rated Welding Output

Amperage Range

Maximum
Open-Circuit
Voltage DC

Amperes Input At Rated

Output, 50Hz - Three-Phase
400 V

KVA

KW

250 A @ 30 VAC,
40% Duty Cycle

5 300

95 VDC

20.2 (0.13*)

14.0 (0.09*)

10.5 (0.04*)

200 A @ 28 VDC,
40% Duty Cycle

5 300

95 VDC

15.1 (0.13*)

10.5 (0.09*)

7.5 (0.04*)

*While idling

3-2. Volt-Ampere Curves

Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.

SA-185 793 / SA-186 294

OM-358 Page 13

3-3. Duty Cycle and Overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 5-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.

250 A @ 40% Duty Cycle For AC

200 A @ 40% Duty Cycle For DC

4 Minutes Welding

6 Minutes Resting

Overheating
0

A or V
15

Minutes

OR
Reduce Duty Cycle
sduty1 5/95 / SA-185 794

OM-358 Page 14

3-4. Selecting a Location

1

Lifting Handles

Use handles to lift unit.

2
Dimensions And Weight
90 lb (40.7 kg) 110 lb (50kg) w/aux power

Hand Cart

Use cart or similar device to move

unit.

24 in
(610 mm)

Rating Label (Non CE

Models)

Use rating label to determine input

power needs.

17 in
(432 mm)

4
5

Plate Label (CE Models)

Line Disconnect Device

Locate unit near correct input

power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
Section 20.

12-1/2 in
(318 mm)
Movement
Y Do not move or operate unit
where it could tip.

1
2

Location And Airflow

5
3

18 in
(460 mm)
4

18 in
(460 mm)

loc_2 3/96 - ST-802 135-A

OM-358 Page 15

3-5. 115 Volts AC Duplex Receptacle, Circuit Breaker CB1 (Optional), And Power Switch
1

AC Duplex Receptacle

115 V 10 A for 230/460 volt models.

115 V 7 A for 400 volt models.

Circuit Breaker CB1

CB1 protects duplex receptacle

from overload.
Press button to reset breaker.
3

Power On/Off Switch

ST-801 866-A

3-6. Weld Output Terminals and Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

Weld Output
Terminals

Work

Electrode

150 ft
(45 m)

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
(105 m)

400 ft
(120 m)

Welding
Amperes

10 60%
Duty
Cycle

60 100%
Duty Cycle

100

1/0

1/0

150

1/0

2/0

3/0

3/0

200

1/0

2/0

3/0

4/0

4/0

250

1/0

2/0

3/0

4/0

2-2/0

2-2/0

300

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

10 100% Duty Cycle

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your
distributor for the mm2 equivalent weld cable sizes.
**Select weld cable size for pulsing application at peak amperage value.
NOTE: For proper installation of gas hose, the use of a quick connect torch (such as Weldcraft QWP-17 or QWP-20), is recommenced.
S-0007E

OM-358 Page 16

3-7. Remote 14 Receptacle Information

Socket*

Socket Information

ST-802 135-A

A
B

J
I

Contactor control, 24 volts dc.

Contact closure to A completes 24 volts dc

contactor control circuit, and enables output.

Output to remote control; 0 to +10 volts dc output

to remote control.

Remote control circuit common.

0 to +10 volts dc input command signal from

remote control.

Current feedback; +1 volt dc per 100 amperes.

AMPERAGE
VOLTAGE

Voltage feedback; +1 volt dc per 10 output

receptacle volts.

GND

Chassis common.

24 VOLTS DC

H
C L N
D M
G
E F

REMOTE
OUTPUT
CONTROL

A/V

*The remaining sockets are not used.

OM-358 Page 17

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

10-Pin Receptacle RC2
Pin Designations
0=No Connection
1=Connected To Ground (Pin G)
Function

A
B
C
D

J
I

No Remote Control

Stick EP Of Current Program

Stick AC Of Current Program

TIG AC Of Current Program

Program 1 Stick EP

Program 2 Stick EP

Program 3 Stick EP

Program 4 Stick EP

Program 1 TIG EN

Program 2 TIG EN

Program 3 TIG EN

Program 4 TIG EN

Program 1 Stick AC

Program 2 Stick AC

Program 3 Stick AC

Program 4 Stick AC

Program 1 TIG AC

Program 2 TIG AC

Program 3 TIG AC

Program 4 TIG AC

G
F
E

ST-802 135-A

*The remaining sockets are not used.

Socket A

Contactor control, 24 volts dc

Socket B

Contact closure to A, completes 24 volts dc contactor

control circuit and enables output

Socket G

Chassis ground

Socket I

Normally open valid arc relay

Socket J

Circuit common for valid arc relay

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

OM-358 Page 18

3-9. Gas Connections

1

Gas Fitting

Fittings have 5/8-18 right-hand

threads.
2

Cylinder Valve

Open valve slightly so gas flow

blows dirt from valve. Close valve.
4

3
4

Regulator/Flowmeter
Flow Adjust

Typical flow rate is 15 cfh (cubic feet

per hour).

Connect customer supplied gas

hose between regulator/flowmeter
and gas fitting on rear of unit.

Tools Needed:
5/8, 1-1/8 in
ST-801 866

3-10. Electrical Service Guide

A. For Multivoltage Units

NOTE

Actual input voltage cannot exceed 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase

Input Voltage

Single-Phase

230

460

230

460

AC

26.5

17.9

62.6

32.2

DC

20.5

13.4

44

25.8

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes

50

25

100

50

Min Input Conductor Size In AWG/Kcmil

10

14

10

104 (32)

165 (50)

90 (27)

241 (74)

10

14

10

Input Amperes At Rated Output

Max Recommended Input Conductor Length In Feet

(Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).

S-0092J

B. For Single Voltage Units

Input Voltage

400

Input Amperes At Rated Output

20.2

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

30

Min Input Conductor Size In AWG/Kcmil

14

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).

125 (38)
14
S-0092J
OM-358 Page 19

3-11. Connecting Input Power

Check input voltage available at
site.
1
2

Input And Grounding

Conductors
Line Disconnect Device

See Section 3-10.

For non-CE three-phase

operation:

Y Always connect green wire

to supply grounding terminal, never to a line terminal.
Connect black, white, and red wires
(L1, L2, L3) to line terminals.

For
CE
operation:

three-phase

Y Always connect green/yellow wire to supply grounding terminal, never to a line

terminal.

2
2

Connect black, brown, and blue

wires (L1, L2, L3) to line terminals.
For single-phase operation:
Y Always connect green wire
to supply grounding terminal, never to a line terminal.

L1
L2

L1

L3

L2

Green
Green Or
Green/Yellow

4
5
6

Y Always connect grounding

conductor first.

Black And White Input

Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape

Insulate and isolate red conductor

as shown.

= GND/PE

1
3

Green
1
6

input_2 3/96 - ST-802 136-A

OM-358 Page 20

SECTION 4 OPERATION
4-1. Controls
A. For 230/460 Volts And Non CE Units (Use With Section 4-2)

22

21
20
6
12

23

24

25

1
26
27
4
5
28

11
10

29

16

17

18

19

13

TIG Function Keys

14

15

Memory
Function
Keys

Stick Function Keys

30

Rear Panel

Ref. ST-188 477-A

OM-358 Page 21

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

22

21
20
6
12

23

24

25

26
27

4
5
28

11
10

29

16
17
18
TIG Function Keys

19

13

14

15

Memory
Function
Keys

Stick Function Keys

30

Rear Panel

ST-186 714-A / Ref. ST-801 866

OM-358 Page 22

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

. For all

front panel switch pad controls:

press switch pad to turn on light and enable
function.

1 Remote Trigger (Normal) Mode

See Section 4-3.
2 Remote Trigger (2T) Hold Mode
See Section 4-4.
3 4T Mode (Specific Trigger Method)
See Section 4-5.
To reconfigure 4T control for use as Spot, Contactor On Lift-Arc , and Mini Logic control, see
Section 4-6.
4 Lift-Arc Start Mode
See Section 4-10.
5 HF Start Mode
See Section 4-10.
6 Encoder Control
Use Encoder Control in conjunction with applicable front panel function switch pads to
change values for that function.
7 Ammeter
Displays amperage and preset parameters for
pulse frequency, % of background amperage,
% of dig, and % of peak time.
8 Voltmeter
Displays arc voltage and the following preset
times (preflow, initial slope, final slope, and
postflow) in seconds, for applicable function
controls.
9 Preflow Time Control
Press switch pad and turn Encoder Control to
set time, 015 seconds, gas flows before welding electrode is energized. Preflow control is
disabled if Lift-Arct Start mode is selected.
Application:
Preflow is used to purge the immediate weld
area of atmosphere. Preflow also aids in consistent arc starting.
10 Initial Amperage Control
Press switch pad and turn Encoder Control to
select a starting amperage, 5300 amps, that
is different from the weld amperage.
Application:
Start current can be used while GTAW welding
to assist in preheating a cold material prior to
depositing filler material.
11 Initial Slope Time Control
Press switch pad and turn Encoder Control to
select length of time, 025 seconds, that it
takes to slope the amperage up/down from
start amperage to weld amperage.
12 TIG Weld Amps And Peak Amps When
Pulse Is Selected
Press switch pad and turn Encoder Control to
select 5300 amps for TIG welding or peak
amps while pulsing.
13 Final Slope Time Control
Press switch pad and turn Encoder Control to
select length of time, 025 seconds, that it takes to slope the amperage up/down from weld
amperage to final amperage.

Application:
Final Slope Time should be used while GTAW
welding materials that are crack sensitive, and/
or the operator wants to eliminate the crater at
the end of the weld.
Note: This applies if the operator is using an
on/off only type control to start and stop the
welding process.
14 Final Amperage Control
Press switch pad and turn Encoder Control to
select 5300 amps of final amperage. Final
amperage is the amperage to which the weld
amperage has sloped up/down to.
15 Postflow Time Control
Press switch pad and turn Encoder Control to
set time, 050 seconds, gas flows after welding
stops.
Application:
Postflow is required to cool tungsten and weld,
and to prevent contamination of tungsten and
weld. Increase postflow time if tungsten or
welds are dark in appearance.
16 Pulser On/Off Control
Press switch pad to turn on light and enable
pulser function.
Application:
Pulsing refers to the alternating raising and
lowering of the weld output at a specific rate.
The raised portions of the weld output are controlled in width, height, and frequency, forming
pulses of weld output. These pulses and the
lower amperage level between them (called the
background amperage) alternately heat and
cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting,
and heat input. Controls can be adjusted while
welding.
Pulsing can also be used for filler material addition technique training.
17 Pulse Frequency Control
Press switch pad and turn Encoder Control to
set pulse frequency, .1500 pps (pulses per
second).
18 Pulse Width Control
Press switch pad and turn Encoder Control to
set percentage of time, 595%, amperage is at
peak for each pulse.
19 Background Amperage Control
Press switch pad and turn Encoder Control to
set background amperage as a percentage,
595%, of peak amperage.
20 AC TIG Process Select Mode
Press switch pad to select AC TIG Process.
21 AC Frequency Control
Press switch pad and turn Encoder Control to
set AC frequency from 20250 Hz (cycles per
second). AC Frequency Control is enabled
only if AC TIG process is selected.
Application:
AC frequency controls bead width and directional control. As AC frequency decreases,
weld bead/puddle gets wider. As AC frequency

increases, weld bead/puddle becomes narrower and the arc becomes more focused.
Travel speed can increase as AC frequency increases.
22 AC Balance Control
Press switch pad and turn Encoder Control to
set percentage of time, 5090%, polarity is
electrode negative. AC Balance Control is enabled only if AC TIG process is selected.
Application:
When welding on oxide forming materials such
as aluminum or magnesium, excess cleaning
is not necessary. To produce a good weld, only
a minimal amount, approximately a 0.10 in
(2.5mm) of etched zone along the weld toes is
required.
Joint configuration, set-up, process variables,
and oxide thickness may affect setting.
Arc rectification can occur when welding above
200 amps and/or while welding with helium
gas. If this condition occurs, increasing the Balance control towards maximum penetration,
may help to restabilize the arc.
23 DC TIG Process Select Mode
Press switch pad to select DCEN (direct current electrode negative) TIG process.
24 14 Program Storage
Each program switch pad, 14, is capable of
storing four welding parameter programs. Four
for AC TIG, four for DCEN TIG, four for AC
Sick, and four for DCEP (direct current electrode positive) Stick. Depending on which process is selected, a total of 16 welding parameter programs can be recalled. The welding parameters are updated to the selected memory
position any time a parameter is changed. To
recall a program, press the desired process select switch pad, and program pad 14.
25 AC Stick Process Select Mode
Press switch pad to select AC Stick process.
AC frequency is fixed at 60 Hz, and AC balance
is fixed at 50% EN (electrode negative). When
the AC Stick Process is select, the DIG function is disabled.
26 DC Stick Process Select Mode
Press switch pad to select DCEP Stick process.
27 Output Contactor Control (Stick)
Press switch pad to enable/disable output.
28 Stick Amperage Control
Press switch pad and turn Encoder Control to
select 5300 amps for Stick welding.
29 DIG Control
Press switch pad and adjust Encoder Control
to set DIG (0100%).
When set lower, short-circuit amperage at low
arc voltage is the same as normal welding amperage.
When set higher, short-circuit amperage is increased at low arc voltage to help with arc starting and making overhead or vertical welds, as
well as to reduce sticking while welding.
30 Power On/Off Switch
Switch located on rear panel.

OM-358 Page 23

4-3.

Remote Trigger (Normal) Mode

1
1

Remote Switch Pad

Press switch pad to activate function.

Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, initial amps, initial
slope, final slope, and final amps are
not functional.
NOTE: Initial weld amperage and final amperage is controlled by the remote device, not by the welding
power source.
NOTE: If On/Off only type trigger is
used, it must be a maintained switch.
All functions become active.
Application: Use Remote Trigger
when the operator desires to use a
foot pedal or finger amperage control.

Current (A)
Torch Trigger Operation
Weld Amps
Initial Slope

Final Slope

Initial Amps
Final Amps
Postflow

Preflow

Push & Hold

Foot Or Finger
Remote Control

OM-358 Page 24

Release For
Maintained Switch

Release Foot Or Finger Remote Control

4-4.

Remote Trigger (2T) Hold Mode

1
1

Remote Trigger Hold Switch

Pad

Press switch pad to activate function.

Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, only trigger input is
functional.
NOTE: Amperage is controlled by
the welding power source.
Application: Use Remote Trigger
Hold (2T) when long extended welds
are made. Remote Trigger Hold (2T)
can help to reduce operator fatigue.

Current (A)
Torch Trigger Operation

Weld Amps
Initial Slope

Final Slope

Initial Amps
Final Amps
Postflow

Preflow

Push & Release Trigger

In Less Than 3/4 Sec.

Push & Release Trigger

In Less Than 3/4 Sec.

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

OM-358 Page 25

4-5.

4T (Specific Trigger Method)

1

4T Switch Pad

Press switch pad to activate function.

Torch trigger operation is as shown.

While in 4T mode, there is a feature
available during the main weld sequence that allows the operator to
toggle between weld current and
final current without breaking the
arc.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by the
welding power source.
Application:
Use 4T trigger method when the
functions of a remote current control
are desired, but only a remote on/off
control is available.
Current (A)
Torch Trigger Operation

Weld Amps
Initial Slope

Final Slope

Initial Amps
Final Amps
Postflow

Preflow

Push & Hold

Trigger

OM-358 Page 26

Release
Trigger

Push & Release

Trigger In Less
Than 3/4 Sec.

Push & Release

Trigger In Less
Than 3/4 Sec.

Push & Hold

Trigger

Release
Trigger

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

1
2

4T Switch Pad
Power Switch

To reconfigure 4T, push and hold 4T

switch pad and turn On power
switch. Hold switch pad for approximately 7 seconds (or until software
version number _ _ _ _ _ _-_clears,
and meters display [-] [H4]).

Rear Panel

Encoder Control

Use Encoder to change functions.

Active function will be displayed on
amperage (right) meter.

H4

Meter Displays

Meter displays for the different functions will be as shown.

Press torch trigger or turn power Off

to save setting. Lift-Arc requires a
power down.
Proceed to Section 4-7 for Mini Logic
operation.
Proceed to Section 4-8 for Spot Control Operation.
Proceed to Section 4-9 for Contactor
On Lift-Arc Operation.

H4

H4L

4T (See Section 4-5)

Mini Logic (See Section 4-7)

SPO

Spot (See Section 4-8)

O1

Lift-Arc

(See Section 4-9)

OM-358 Page 27

4-7. Mini Logic Operation

1
1

Mini Logic Meter Display

Select Mini Logic according to Section 4-6.

Torch trigger operation is as shown.

H4L

Mini Logic

During Mini Logic welding operation, the weld current can be manually changed from the initial amps
level to the main weld amps level by
pressing and releasing the torch
trigger in less than 3/4 seconds.
Application: This ability to change
current levels without either initial
slope or final slope, gives the operator the opportunity to adjust filler
metal without breaking the arc.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.

Torch Trigger Operation

Current (A)

Weld Amps

Final Slope
Rate

Initial Slope

Final Slope

Start Amps
Initial Amps
Final Slope
Rate

Preflow

Push & Hold

Trigger

Push & Hold

Trigger For More
Than 3/4 Sec.

Release Trigger

OM-358 Page 28

Postflow

Push & Release

Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.

Push & Release

Trigger In Less
Than 3/4 Sec.

Push & Hold

Trigger For More
Than 3/4 Sec.

Push & Release

Trigger In Less
Than 3/4 Sec.

Push & Hold

Trigger For More
Than 3/4 Sec.

4-8. Spot Control Operation

1

Spot Function Meter Display

Select Spot function according to

Section 4-6.

SPO

Spot

TIG Weld Amps And Peak

Amps While Pulsing Switch
Pad
Encoder Control

Set spot parameters as follows:

Press switch pad once (amps LED
lights) and turn Encoder to set spot
amperage. Press switch pad again
(seconds LED lights) and turn Encoder to set spot time (.125 seconds).
Torch trigger operation is as shown.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.

Application: To provide a timed

weld. Used for tacking, and thin
sheet joining.

Current (A)
Torch Trigger Operation
Timed Spot Weld Amps

Preflow

Push & Hold

Trigger

Postflow

Release
Trigger

NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will be
displayed (see Section 5-3).
OM-358 Page 29

4-9. Contactor On Lift-Arc Operation

1

Contactor On Lift-Arc Meter

Display

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

Proceed to Section 4-10 Lift-Arc
start procedures.

O1

Lift-Arc

Application: Lift-Arc is used for the

DCEN GTAW process when the HF
start method is not permitted, or to
replace the scratch start method.
Also, allows for the use of Lift-Arc
without a remote on/off switch.

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

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

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

Touch

12
Seconds

TIG Electrode

Workpiece

Touch tungsten electrode to workpiece at weld start point, enable output with torch trigger, foot control, or
hand control. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. An arc will form
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Application:

Do NOT Strike Like A Match!

Lift-Arc is used for the DCEN

GTAW process when HF Start
method is not permitted, or to replace the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to help
start arc when output is enabled.
High frequency turns off when arc is
started, and turns on whenever arc
is broken to help restart arc.

Ref. ST-156 279

OM-358 Page 30

4-11. Programmable HF Start Amperage And Time Modes

A.

Accessing Programmable HF Start Amperage And Time Modes

NOTE: Before accessing programmable HF start amperage and time
modes, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while programmable HF start and
time modes are active.
1
2

Lift-Arc And HF Start Mode

Key Pads
Power Switch

To display the programmable HF

start amperage and time screens,
push and hold Lift-Arc and HF Start
switch pads and turn On power
switch. Hold switch pads for
approximately 7 seconds (or until
software version number _ _ _ _ _
_-_clears meters).

Proceed to Section B and/or C.

Rear Panel

B.

Setting Programmable HF Start Amperage

3

30

1
Or

NOTE: Before accessing programmable

HF start amperage mode, be sure that all
procedures and parameters are established. Parameter adjustment is limited
while programmable HF start amperage
mode is active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1

Initial Amps Switch Pad

2 Memory Program Switch Pads (14)

3 Encoder Control
To adjust DCEN or AC HF start amperage
proceed as follows:
Press desired TIG process switch pad (AC
TIG or DC TIG) to activate desired process
and turn On LED.
Press desired memory switch pad (14) to
activate desired memory program and turn
on LED.
Press Initial Amps switch pad. Switch pad
LED turns on, meter A LED turns on, and
[5 ] [30 ] is displayed on meters.

The 30 displayed on the amps meter is

AC start amps and 20 is DC start amps
(these are factory default settings), and can
be adjusted from 1 to 200 amps by turning
the Encoder control.
To change start time, proceed to Section C.
To save changes to HF start amperage
without changing start time, select a different memory program number, or turn power Off.

OM-358 Page 31

C. Setting Programmable Start Time

20

Or

NOTE: Before accessing programmable

start time mode, be sure that all procedures
and parameters are established. Parameter adjustment is limited while programmable start time mode is active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1
2

Initial Slope Switch Pad

Memory Program Switch Pads (14)

OM-358 Page 32

Encoder Control

To adjust start time proceed as follows:

Press desired TIG process switch pad (AC
TIG or DC TIG) to activate desired process
and turn On LED.
If you are adjusting start time without having adjusted start amperage in Section B,
press desired memory switch pads (14) to
activate desired memory program and turn
on LED.

Press Initial Slope switch pad. Switch pad

LED turns on, meter S LED turns on, and
[5 ] [20] is displayed on meters.
The [20 ] displayed on the amps meter is AC
start time, and [3 ] is DC start time (these
are factory default settings), and can be adjusted from 1 to 200 milliseconds by turning
the Encoder control.
To save changes, select a different
memory program number, or turn power
Off.

4-12. Arc Timer/Counter Display

1
2

To display the arc timer/counter,

push and hold Initial and Final Slope
control switch pads, and turn On
Power switch. Hold switch pads for
approximately 7 seconds (or until
software version number
_ _ _ _ _ _-_clears meters).

And

Arc Counter

456

999

999

Arc Counter

After 5 seconds, the meter A and

Memory 2 LEDs turn on, and the arc
counter will be displayed for the
next 5 seconds as [000 000 ] to [999
999]. The maximum arc cycle count
is 999 999.

Rear Panel

123

Arc Timer Display

Upon power up as described

above, the meter S and Memory 1
LEDs will turn on, and arc time will
be displayed for 5 seconds as [000
000 ] to [999 999 ]. The first four numbers indicate hours, and the last two
numbers indicate minutes. Arc time
shown in example is read as 1,234
hours and 56 minutes. Maximum
arc time is 9,999 hours and 59 minutes.
4

Arc Timer

Initial And Final Slope Control

Switch Pads
Power Switch

OM-358 Page 33

4-13. Lock Out Functions

A. Accessing Lock Out Capability
3

L0
4

L1

or 2,3,4

Rear Panel

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

Section 4-13.
There are four (14) different lock out levels. Each successive level
allows the operator more flexibility.
NOTE: Before activating lock out levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lock out levels are active.
1 Memory Program Buttons 3 And 4
2 Power Switch
To access lock-out screens, press and hold memory program switch
pads 3 and 4, and turn On power switch. Hold switch pads for
approximately 7 seconds (or until software version number _ _ _ _
_ _-_clears meters).
3 Lock Out Off
If meter display is as shown, lockout feature is off.
4 Lock-Out On
If meter display is as shown, lockout feature is on.
To turn On the lock out feature, proceed as follows:
Enter a three digit code using the four Memory Program switch pads.
NOTE: If any switch pad other than a numbered Memory Program

OM-358 Page 34

switch pad is used, the lock out code is cancelled, and the lock out
condition will remain inactive.
Once three digits have been entered, the amperage screen display
will change from [L0 ] to [L ].
There are four lock out levels available. Enter any single digit (14),
using the Memory Program switch pads, to access a lock out level
(see Sections B and/or A).
Press torch trigger or turn Off power to complete lock out On
sequence.
To turn Off the lock out feature, proceed as follows:
To access lock-out screens, press and hold memory program switch
pads 3 and 4, and turn On power switch. Hold switch pads for
approximately 7 seconds (or until software version number
_ _ _ _ _ _-_clears meters).
Enter the same three digits that were used to turn on the lock out feature. NOTE: If any switch pad other than a numbered Memory Program key pad is used, the code is cancelled, and the lock out condition will remain On.
Once the correct three digits have been entered, the amperage
screen display will change from [L1 ] or 2,3,4 to [L0 ].
Press torch trigger or turn Off power to complete lock out Off
sequence.

B. Lock Out Levels

Level 1

Level 1
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 1.
Trigger Selection
Allows for normal, 2T, or 4T trigger
mode to be selected if the TIG process was selected when lock out
feature was activated.

Or
Or
Trigger Selection (TIG)

Contactor Control (Stick)

Stick Contactor Control

Allows for contactor control if the
Stick process was selected when
lock out feature was activated.

Level 2

Level 2

Select desired program

NOTE: Before activating lock out

levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 2.
Includes all the functions of level 1
plus the following:

Program Selection

Program Selection 14
Gives operator the ability to select
desired program.
Process Selection TIG or Stick
Gives operator the ability to select
the TIG or Stick process.
Lift-Arc Or HF Start Mode

Or

Select TIG
or Stick

Gives operator the ability to select

Lift-Arc or HF Start mode.

Process Selection

Or
Select Lift-Arc Or
HF Start mode
Lift-Arc Or HF Start Mode Selection

OM-358 Page 35

C. Lock Out Levels (Continued)

Level 3
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited while
lock out levels are active.

Level 3

Note: Remote amperage control is

not available in level 3.
Includes all the functions of levels 1
and 2 plus the following:
+/ 10% adjustment of preset TIG
Weld Amps or Peak Amps While
Pulsing or Stick Weld Amps
Select TIG or Stick
Amperage control,
and use Encoder to
adjust amperage.

Select desired amperage control

(TIG or Stick, and use Encoder control to adjust amperage +/ 10% of
preset amperage value, up to the
limits of the machine.
Pulser ON/Off Control
Gives operator the ability to turn on/
off the Pulser control.
Level 4

+/ 10 % Amperage Adjust Control

NOTE: Before activating lock out

levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited while
lock out levels are active.
Includes all the functions of levels 1,
2, and 3 plus the following:
Remote Amperage Control
Allows operator to use remote amperage control if desired. Remote
control operates from minimum to
maximum of preset amperage value. Connect remote control device
according to Section 3-7.

Turn Pulser control on/off

Pulser On/Off Control

Level 4

A
Remote Amperage Control

OM-358 Page 36

J
I

H
C L N
D M
G
E F

SECTION 5 MAINTENANCE AND TROUBLESHOOTING

5-1. Routine Maintenance
Y Disconnect power before maintaining.

3 Months
Replace
unreadable
labels.

Replace damaged
gas hose.

Clean and
tighten weld
terminals.

Repair or replace cracked

cables and cords.

6 Months

Blow out inside. During heavy

service, clean monthly.

5-2. Blowing Out Inside of Unit

Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.

ST-802 135-A

OM-358 Page 37

5-3. Voltmeter/Ammeter Help Displays

V

HE.L

P6

HE.L

P7

HE.L

P8

HE.L

P0

HE.L

P1

HE.L

P2

HE.L

P9

HE.L

P10

HE.L

P3

10

HE.L

P4

HE.L

P5

. All directions are

in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
0 Help 0 Display
Indicates a short in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
1 Help 1 Display
Indicates a malfunction in the primary power circuit. Contact a Factory Authorized
Service Agent if this display is shown.
2 Help 2 Display
Indicates an open in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
3 Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the

OM-358 Page 38

fan to cool it (see Section 3-3). Operation

will continue when the unit has cooled.
4

Help 4 Display

Indicates an open in the thermal protection

circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
5

Help 5 Display

Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 3-3). Operation
will continue when the unit has cooled.
6

Help 6 Display

Indicates that the input voltage is too low

and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (10%). Have an
electrician check the input voltage if this display is shown.
7

Help 7 Display

Indicates that the input voltage is too high

and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (10%). Have an
electrician check the input voltage if this display is shown.
8

Help 8 Display

Indicates a malfunction in the secondary

power circuit of the unit. Contact a Factory
Authorized Service Agent if this display is
shown.
9

Help 9 Display

Indicates a short in the thermal protection

circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
10 Help 10 Display
Indicates torch trigger is depressed. Release trigger to continue.

5-4. Troubleshooting

Trouble
No weld output; unit completely
inoperative.

Remedy
Place line disconnect switch in On position (see Section 3-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-11).
Check for proper input power connections (see Section 3-11).

No weld output; meter display On.

If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Sections 4-1 and 3-7).
Input voltage outside acceptable range of variation (see Section 3-10).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-3).

Erratic or improper weld output.

Use proper size and type of weld cable (see Section 3-6).
Clean and tighten all weld connections.

No 115 volts ac output at duplex receptacle.

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

Fan not operating.

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

Wandering arc

Use proper size tungsten.

Use properly prepared tungsten.
Reduce gas flow rate.

Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.

OM-358 Page 39

SECTION 6 ELECTRICAL DIAGRAM

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

OM-358 Page 40

SC-191 702-A

OM-358 Page 41

Figure 6-2. Circuit Diagram For 400 Volt Non-CE Models

OM-358 Page 42

SD-191 704-A

OM-358 Page 43

Figure 6-3. Circuit Diagram For 400 Volt CE Models

OM-358 Page 44

SD-188 024-A

OM-358 Page 45

SECTION 7 HIGH FREQUENCY

7-1. Welding Processes Requiring High Frequency
1

High-Frequency Voltage

TIG helps arc jump air gap

between torch and workpiece and/
or stabilize the arc.

Work
TIG

high_freq 12/96 S-0693

7-2. Incorrect Installation

Weld Zone
11, 12
50 ft
(15 m)

10
14

9
8
7
3
2

13

1
4

Sources of Direct High-Frequency

Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table

Sources of Conduction of High

Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring

Sources of Reradiation of High

Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines

S-0694

OM-358 Page 46

7-3. Correct Installation

Weld Zone
3

50 ft
(15 m)

50 ft
(15 m)

2
8
4

8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.

Nonmetal
Building

Ground
workpiece
if required
by codes.

Metal Building

8
8
11

10
Ref. S-0695 / Ref. S-0695

High-Frequency Source (welding

power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.

Conduit Joint Bonding and Grounding

Electrically join (bond) all conduit sections

using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6

Water Pipes and Fixtures

Metal Building Requirements

9

Metal Building Panel Bonding Methods

Bolt or weld building panels together, install

copper straps or braided wire across seams,
and ground frame.

Ground water pipes every 50 ft (15 m).

10 Windows and Doorways

Cover all windows and doorways with

grounded copper screen of not more than
1/4 in (6.4 mm) mesh.

External Power or Telephone Lines

Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.
8

Grounding Rod

Consult the National Electrical Code for

specifications.

11 Overhead Door Track

Ground the track.

OM-358 Page 47

SECTION 8 SELECTING AND PREPARING

TUNGSTEN ELECTRODE
gtaw 7/97

NOTE

For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.

8-1. Selecting Tungsten Electrode

Amperage Range - Gas Type - Polarity
Electrode Diameter

DC Argon Electrode
Negative/Straight Polarity

DC Argon Electrode
Positive/Reverse Polarity

AC Argon Using
High Frequency

AC Argon Balanced
Wave Using High Freq.

.010

Up to 25

Up to 20

Up to 15

.020

15-40

15-35

5-20

2% Thorium Alloyed
Tungsten (Red Band)

.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

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 electrode
manufacturers.

8-2. Safety Information About Tungsten

Y Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-level radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1
2

Tungsten Electrode With

Balled End
Pointed Tungsten Electrode
Ref. S-0161

Om-358 Page 48

8-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding

1

1
2

Tungsten Electrode
Tapered End

Grind end of tungsten on fine grit,

hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.

2-1/2 Times
Electrode Diameter

1
2
3

1
2

Stable Arc
Flat

Diameter of this flat determines

amperage capacity.
3
4

Grinding Wheel
Straight Ground

1
2
3
4

Arc Wander
Point
Grinding Wheel
Radial Ground

4
Ideal Tungsten Preparation Stable Arc

2
3

4
Wrong Tungsten Preparation Wandering Arc
Ref. S-0161 / Ref. S-0162

OM-358 Page 49

SECTION 9 GUIDELINES FOR TIG WELDING (GTAW)

9-1. Positioning The Torch

3
2

4
90
1

Y Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust contains low-level
radioactive material. Properly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1

Workpiece

Make sure workpiece is clean

before welding.
2

Work Clamp

Place as close to the weld as

possible.

1015
4
5
6

1025

3
4
5
6

Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode

Select and prepare tungsten

according to Sections 8-1 and 8-3.
Guidelines:

1/16 in
3/16 in
Bottom View Of Gas Cup

The inside diameter of the gas cup

should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.

Ref. ST-161 892

Om-358 Page 50

9-2. Torch Movement During Welding

Tungsten Without Filler Rod
75

Welding direction

Form pool

Tilt torch

Move torch to front

of pool. Repeat process.

Tungsten With Filler Rod

75

Welding direction

Form pool

Tilt torch

Remove rod

15

Add filler metal

Move torch to front

of pool. Repeat process.
ST-162 002-B

OM-358 Page 51

9-3. Positioning Torch Tungsten For Various Weld Joints

90
Butt Weld And Stringer Bead

70

20

20
T Joint
70

10

20

40

Lap Joint
70

20
30

90
Corner Joint

70

20

ST-162 003 / S-0792

Om-358 Page 52

Notes

OM-358 Page 53

SECTION 10 PARTS LIST

20

. Hardware is common and

PC2

13

27

14

29

28
31

PC1

PC8

39

39

20

38

37

37

40

41

36

35

34

33

32

(Fig.102)42

30(PC3)

11

10

12

15

16

26

17

25

18

24

43

23

19

22

21

not available unless listed.

Figure 10-1. Main Assembly

OM-358 Page 54

ST-801 870-C

Quantity
Model
Item
No.

Dia.
Mkgs.

Part
No.

Description

230/460

400 CE

400
Non CE

Figure 10-1. Main Assembly

. . . 1 . . . . . . . . . . . . . 126 416 . .
. . . 2 . . . . . . . . . . . . . 126 415 . .
. . . 3 . . . . . . . . . . . . . 138 442 . .
. . . 4 . . . . . . . . . . . . +175 148 . .
. . . . . . . . . . . . . . . . . . . 175 256 . .
. . . 5 . . . . . . . . . . . . . 134 327 . .
. . . 6 . . . PC8 . . . . . 182 188 . .
. . . . . . . . PLG21 . . . . 115 094 . .
. . . . . . . . PLG22 . . . . 115 093 . .
. . . 7 . . . . . . . . . . . . . 183 613 . .
. . . 8 . . . . . . . . . . . . . 182 498 . .
. . . 9 . . . PC1 . . . . . 191 395 . .
. . . . . . . . PLG2 . . . . . 115 091 . .
. . . . . . . . PLG3 . . . . . 115 092 . .
. . . . . . . . PLG4 . . . . 131 054 . .
. . . . . . . . PLG5 . . . . . 115 091 . .
. . . . . . . . PLG7 . . . . 130 203 . .
. . . . . . . . PLG8 . . . . . 115 092 . .
. . . . . . . . PLG9 . . . . 131 204 . .
. . . . . . . . PLG10 . . . . 115 094 . .
. . . 10 . . . . T2 . . . . 193 311 . .
. . . 10 . . . . T2 . . . . 193 310 . .
. . . 11 . . . . . . . . . . . . 187 461 . .
. . . 12 . . . . T2 . . . . . 189 536 . .
. . . 12 . . . . T2 . . . . . 180 873 . .
. . . . . . . . RC10 . . . . 166 679 . .
. . . . . . . . PLG10 . . . 166 680 . .
. . . 13 . . . GS1 . . . . . 133 873 . .
. . . 14 . . . . . . . . . . . . 189 033 . .
. . . 15 . . . CB1 . . . . 083 432 . .
. . . 15 . . . CB1 . . . . 161 078 . .
. . . 16 . . . . . . . . . . . . . 605 227 . .
. . . 17 . . . . . . . . . . . . . 182 205 . .
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . 175 282
. . . 20 . . . . . . . . . . . . . 175 138
. . . 21 . . . . . . . . . . . . . 182 561
. . . 21 . . . . . . . . . . . . . 179 625
. . . 22 . . . . . . . . . . . . . 175 213
. . . 22 . . . . . . . . . . . . . 186 440
. . . 23 . . . . . . . . . . . . . 182 445
. . . 24 . . . . . . . . . . . . . 176 226
. . . 25 . . . . S1 . . . . . 128 756
. . . 26 . . . PC2 . . . . . 185 090
. . . . . . . . . . . . . . . . . . . 176 879
. . . . . . . . PLG13 . . . 131 204
. . . . . . . . PLG14 . . . . 115 094
. . . . . . . . . . . . . . . . . . . 179 626
. . . 27 . . . . . . . . . . . . +175 132
. . . . . . . . . . . . . . . . . . . 126 026
. . . 28 . . . . . . . . . . . . . 173 693
. . . 29 . . . . . . . . . . . . . 176 736
. . . 30 . . . PC3 . . . . . 190 364
. . . . . . . . DD1-6 . . . . 186 914
. . . . . . PLG17, 18 . . 131 054
. . . . . . . . PLG26 . . . . 115 091

HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
INSULATOR, side RH & LH . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
CIRCUIT CARD ASSEMBLY, clamp . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
INSULATOR, PC card clamp . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
BRACKET, mtg PC card clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
VALVE, 24VDC 2way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
RECEPTACLE, str dx grd 2P 3W 15A . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CIRCUIT BREAKER, 1P 10A 250VAC . . . . . . . . . . . . . . 1
CIRCUIT BREAKER, 1P 7A 250VAC . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
PLATE, identification rear
(order by model and serial number) . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
. . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 1
. . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUSHING, strain relief .472/.787 ID . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 1
. . BUSHING, strain relief .350/.630 ID . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . NUT, stl locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . SWITCH, tgl 3PST 40A 600VAC (Power Switch) . . . . . 1 . . . . . 1 . . . . . 1
. . CIRCUIT CARD, assembly . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . SCREW, M5.82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . 18 . . . . 18
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . 4
. . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . 4
. . CIRCUIT CARD, front panel (consisting of) . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . . . LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . 6 . . . . . 6
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
OM-358 Page 55

Quantity
Model
Item
No.

Dia.
Mkgs.

Part
No.

Description

230/460

400 CE

400
Non CE

Figure 10-1. Main Assembly (Continued)

. . . . . . . . PLG11 . . . . . 115 092
. . . 31 . . . FM . . . . . 175 084
. . . . . . . . . . . . . . . . . . . 135 635
. . . 32 . . . . . . . . . . . . . 191 571
. . . 33 . . . . . . . . . . . . . 191 173
. . . 33 . . . . . . . . . . . . . 191 172
. . . 33 . . . . . . . . . . . . 191 172
. . . 34 . . . RC2 . . . . 191 302
. . . 34 . . . RC2 . . . . 191 302
. . . 35 . . . RC1 . . . . . 188 186
. . . 36 . . . . . . . . . . . . . 192 018
. . . 37 . . . . . . . . . . . . . 185 703
. . . 38 . . . . . . . . . . . . . 187 235
. . . 38 . . . . . . . . . . . . . 188 192
. . . 39 . . . C7,8 . . . . 186 543
. . . 40 . . . . . . . . . . . . . 186 446
. . . 40 . . . . . . . . . . . . . 189 229
. . . 41 . . . . . . . . . . . . . 186 952
. . . 42 . . . . . . . . . . . . . Fig 10-2
. . . 43 . . . . . . . . . . . . . 182 108

..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..

RECEPTACLE, w/leads & plug . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .

MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
NAMEPLATE, RH (order by model and serial number) 1 . . . . . 1
NAMEPLATE, RH (order by model and serial number) . . . . . . . . 1
NAMEPLATE, RH (order by model and serial number) 1 . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
NAMEPLATE, LH (order by model and serial number) . 1 . . . . . 1 . . . . .
RECEPTACLE, twist lock assembly . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
RECEPTACLE, female gas . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
RECEPTACLE, male gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . 1
NAMEPLATE, (order by model and serial number) . . . . 1 . . . . . 1 . . . . .
KNOB, encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
WINDTUNNELS w/COMPONENTS . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1
1
1
1
1
1
1
1
2
1
2
1
1
1

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

OM-358 Page 56

. Hardware is common and

not available unless listed.

3

11
5

10
6
7

12

16

13
14
15
37
36
35

17
34

18

33
31
32

30
19
20
21

29

22
28

23
27

24
26

25

ST-801 871-E

Figure 10-2. Windtunnels w/Components

Quantity
Model
Item
No.

Dia.
Mkgs.

Part
No.

Description

230/460

400 CE

400
Non CE

Figure 10-2. Windtunnels w/Components

(Fig 10-1 Item 39)
. . . 1 . . . . . C11,12 . . . . 185 424
. . . 2 . . . . . C9,10 . . . . 164 812
. . . 3 . . . . . . HD1 . . . . . 182 918
. . . 4 . . . . . . . . . . . . . . . +182 206
. . . . . . . . . . . . . . . . . . . . . . 153 718
. . . . . . . . . . . . . . . . . . . . . . 126 026
. . . 5 . . . . . . . . . . . . . . . . 185 424
. . . 6 . . . . R1,C5,6 . . . 175 194
. . . 7 . . . . . . D1,2 . . . . . 185 775
. . . 8 . . . . . . . . . . . . . . . . 188 361
. . . 9 . . . . . . . . . . . . . . . . 182 208
. . . 10 . . . . . . . T3 . . . . . . 182 667
. . . 11 . . . . . . . . . . . . . . . . 183 073
. . . 12 . . . . . . . . . . . . . . . . 182 499
. . . 13 . . . . . . . . . . . . . . . . 182 806
. . . 14 . . . . . . C3,4 . . . . . 174 980
. . . 15 . . . . W1,2,2A . . . 175 082

..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..

CAPACITOR, filter assembly . . . . . . . . . . . . . . . . . . . . 1 . . . . .

CAPACITOR, polyp met film 1MF 600 . . . . . . . . . . . . 2 . . . . .
TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . 1 . . . . .
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
LABEL, warning exploding parts . . . . . . . . . . . . . . . . . 2 . . . . .
LABEL, warning electric shock . . . . . . . . . . . . . . . . . . 2 . . . . .
CAPACITOR, filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
TRANSFORMER, coupling . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
INSULATOR, PC card HF . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
ENCLOSURE, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
BRACKET, mtg contactor/capacitor/PC board . . . . . 1 . . . . .
CAPACITOR, elctlt 2700uf 420VDC . . . . . . . . . . . . . . 2 . . . . .
CONTACTOR, def prp 40A 7P . . . . . . . . . . . . . . . . . . 1

1
2
1
1
2
2
2
1
1
2
1
1
1
1
1
2

.....
.....
.....
.....
.....
.....

1
2
1
1
2
2

.....
.....
.....
.....
.....
.....
.....
.....
.....

1
1
2
1
1
1
1
1
2

OM-358 Page 57

Quantity
Model
Item
No.

Dia.
Mkgs.

Part
No.

Description

230/460

400 CE

400
Non CE

Figure 10-2. Windtunnels w/Components

(Fig 10-1 Item 39) (Continued)
. . . . . . . . . . . . . . . . . . . . . . 173 763
. . . 16 . . . . . . . T1 . . . . . . 183 014
. . . 17 . . . . . . . L2 . . . . . . 183 009
. . . 18 . . . . . . . L1 . . . . . . 187 522
. . . 19 . . . . . . PC9 . . . . . 187 264
. . . 20 . . . . . . . . . . . . . . . . 187 463
. . . 21 . . . . . . C1 . . . . . 186 549
. . . 22 . . . . . . . . . . . . . . . . 025 248
. . . 23 . . . . . . CT1 . . . . . 175 199
. . . 24 . . . . . . . . . . . . . . . . 177 547
. . . 25 . . . . . . . . . . . . . . . . 175 140
. . . 26 . . . . . . . . . . . . . . . . 181 197
. . . 27 . . . . . . L3,4 . . . . . 175 482
. . . 28 . . . . . . . . . . . . . . . . 109 056
. . . 29 . . . . . . . . . . . . . . . +187 460
. . . 30 . . . . . . . . . . . . . . . . 141 690
. . . 31 . . . . . . PC7 . . . . . 191 397
. . . . . . . . . . . . . F1 . . . . . . 012 633
. . . . . . . . . . . . . . . . . . . . . . 188 109
. . . . . . . . . . . PLG19 . . . . 115 092
. . . . . . . . . . . PLG20 . . . . 131 054
. . . 32 . . . . . . SR1 . . . . . 179 629
. . . 33 . . PM1,2/PC4,5 . 179 628
. . . . . . . . . . . RT1,2 . . . . 173 632
. . . 34 . . . . . . . . . . . . . . . . 173 631
. . . 35 . . . PM3,4/PC6 . . 185 776
. . . . . . . . . . . PLG23 . . . . 115 091
. . . 36 . . . . . . . . . . . . . . . . 182 641
. . . 37 . . . . . . . . . . . . . . . . 182 642

. . STAND-OFF, No. 10-32 x 1.418 lg . . . . . . . . . . . . . . . 1 . . . . .

. . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . CIRCUIT CARD ASSEMBLY, input filter . . . . . . . . . . . . . . . . . .
. . BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp .27uf 1000VDC . . . . . . . . . . . . . . 1 . . . . .
. . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . 2 . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . GASKET, DI-DT rubber . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . COIL, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . .
. . CIRCUIT CARD, HF (consisting of) . . . . . . . . . . . . . . 1 . . . . .
. . . . FUSE, mintr gl 1A 250V . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . 2 . . . . .
. . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . KIT, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BUS BAR, diode IGBT . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BUS BAR, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .

1
1
1
1
1
1
1
2
1
1
1
1
2
2
1
4
1
1
2
1
1
1
1
2
1
1
1
1
1

.....
.....
.....
.....

1
1
1
1

.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....

1
2
1
1
1
1
2
2
1
4
1
1
2
1
1
1
1
2
1
1
1
1
1

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

OM-358 Page 58

Effective January 1, 1998

(Equipment with a serial number preface of KJ 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 conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin,
warrants to its original retail purchaser that new Miller
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING
THE
WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an International distributor.
1.

2.

5 Years Parts 3 Years Labor

*

Original main power rectifiers

Inverters (input and output rectifiers only)

3 Years Parts and Labor

*

3.

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 by the
engine manufacturer.)

1 Year Parts and Labor

*

Motor Driven Guns (w/exception of Spoolmate 185)

Process Controllers

Positioners and Controllers

Automatic Motion Devices

Robots

IHPS Power Sources

Water Coolant Systems

HF Units

Grids

Spot Welders

Load Banks

SDX Transformers

Miller Cyclomatic Equipment

Running Gear/Trailers

Plasma Cutting Torches (except APT, ZIPCUT &

PLAZCUT Models)

Deutz Engines (outside North America)

Field Options
(NOTE: Field options are covered under True Blue
for the remaining warranty period of the product they
are installed in, or for a minimum of one year
whichever is greater.)

4.

6 Months Batteries

5.

90 Days Parts and Labor

*

MIG Guns/TIG Torches

APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches

Remote Controls

Accessory Kits

Replacement Parts (No labor)

Spoolmate 185

Millers True Blue Limited Warranty shall not apply to:

1.

Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.

2.

Consumable components; such as contact tips, cutting

nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.

3.

Equipment that has been modified by any party other

than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customers risk and expense. Millers option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.

miller_warr 1/98

Owners Record
Please complete and retain with your personal records.
Model Name

Serial/Style Number

Purchase Date

(Date which equipment was delivered to original customer.)

Distributor
Address
City
State

Zip

Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.

Welding Supplies and Consumables

Options and Accessories
Personal Safety Equipment
Service and Repair

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Replacement Parts
Training (Schools, Videos, Books)

International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams

European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

Welding Process Handbooks

www.MillerWelds.com

Contact the Delivering Carrier for:

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims,

contact your distributor and/or equipment
manufacturers Transportation Department.

PRINTED IN USA

1998 Miller Electric Mfg. Co.

9/98