uputstvo za argonski aparat lj 490732 l

8/9/2019 Uputstvo Za Argonski Aparat LJ 490732 L

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Visit our website at

www.MillerWelds.com

Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

OM-2240 207688X200811

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

Dynasty 200 SD And DX

(Including Optional Cart And CoolerCE And Non-CE Models


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Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

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

line catalog or individual specification sheets. To locate your nearest

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

www.MillerWelds.com on the web.

Thank youand congratulationson choosing Miller. Now you can get

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

it any other way.

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

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

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

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

best you could buy.

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

tradition. Theyre just as committed to providing equipment and service

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

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

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

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

Weve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

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

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

From Miller to You

Mil_Thank 4/05


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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION 3 DEFINITIONS (CE Models) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Warning Label Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. WEEE Label (For Products Sold Within The EU) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3. Symbols And Definitions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Serial Number And Rating Label Location 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Specifications 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. DC Volt-Ampere Curves 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. AC Volt-Ampere Curves 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Duty Cycle And Overheating 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Selecting A Location 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Weld Output Terminals And Selecting Cable Sizes* 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8. Remote 14 Receptacle Information 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Gas Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. TIG HF Impulse/ Lift-Arct Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Stick Connections 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. TIGRunner Connections 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13. Electrical Service Guide 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14. Connecting Three-Phase Input Power 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15. Connecting Single-Phase Input Power 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Encoder Control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Amperage Control 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Ammeter And Parameter Display 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Voltmeter 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Polarity Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Lift-ArcE And HF TIG Start Procedures 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Process Control 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9. Output Control 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10. Pulser Control (DX Models Only) 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11. Sequencer Controls (DX And CE Models) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12. Adjust Controls (Preflow/Post Flow/DIG/Purge) 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13. AC Waveshape 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) 34. . . . . . . . . . . . . . . . . . . . . . . . . . .5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On

The Front Panel 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16. Factory Parameter Defaults And Range And Resolution 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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5-17. Resetting Unit To Factory Default Settings 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 6 ADVANCED FUNCTIONS 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Programable TIG Start, And Preset Amperage Minimum Parameters 38. . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. AC Waveshape Selection 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Output Control And Trigger Functions 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Arc Timer/Counter Display 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Lockout Functions 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6. Setting Unit To Display PPP While Pulse Welding (DX Models Only) 58. . . . . . . . . . . . . . . . . . . . . . . . . . .6-7. Stick Open-Circuit Voltage (OCV) Selection 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8. Stick Stuck Check Selection 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 MAINTENANCE AND TROUBLESHOOTING 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Blowing Out Inside Of Unit 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Voltmeter/Ammeter Help Displays 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Troubleshooting 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 ELECTRICAL DIAGRAMS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 HIGH FREQUENCY (HF) 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Welding Processes Requiring High Frequency 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Correct Installation 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 SETUP GUIDES FOR (GTAW) TIG WELDING 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Typical GTAW Set-Ups 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTERMACHINES 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 70. . . . . . . .11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter

Machines 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 12 GUIDELINES FOR (GTAW) TIG WELDING 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Positioning The Torch 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2. Torch Movement During Welding 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3. Positioning Torch Tungsten For Various Weld Joints 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 SETUP GUIDE FOR (SMAW) STICK WELDING 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 73. . . . . . . . . . . . . . . . . . . . . . .SECTION 14 GUIDELINES FOR (SMAW) STICK WELDING 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-1. Electrode and Amperage Selection Chart 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-2. Stick Welding Procedure 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3. Striking an Arc Scratch Start Technique 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-4. Striking an Arc Tapping Technique 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-5. Positioning Electrode Holder 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-6. Poor Weld Bead Characteristics 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-7. Good Weld Bead Characteristics 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-8. Conditions That Affect Weld Bead Shape 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-9. Electrode Movement During Welding 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-10. Butt Joints 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-11. Lap Joint 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-12. Tee Joint 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-13. Weld Test 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-14. Troubleshooting Porosity 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15. Troubleshooting Excessive Spatter 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16. Troubleshooting Incomplete Fusion 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-17. Troubleshooting Lack Of Penetration 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18. Troubleshooting Excessive Penetration 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-19. Troubleshooting Burn-Through 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-20. Troubleshooting Waviness Of Bead 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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14-21. TroubleshootingDistortion 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 15 PARTS LIST 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 16 COOLER PARTS LIST 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 17 CART PARTS LIST 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND ACCESSORIESWARRANTY


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241514-A

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A.declares thatthe product(s) identified in this declaration conform to the essential requirements and

provisions of the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

Dynasty 200 DX 907356

Council Directives:

2006/95/EC Low Voltage

2004/108/EC Electromagnetic Compatibility

2006/42/EEC Machinery Directive

Standards:

IEC 60974-1 Arc Welding Equipment - Welding Power Sources: edition 3, 2005-07.

IEC 60974-3 Arc Welding Equipment Arc Striking and Stabilizing Devices: edition 1, 2003-07.

IEC 60974-10 Arc Welding Equipment - Electromagnetic Compatibility Requirements: edition 1.1,

2004-10.

US Signatory:

November 25, 2008

__________________________________________________________________________

David A. Werba Date of Declaration

MANAGER,PRODUCTDESIGNCOMPLIANCE


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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _200704

7

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

1-1. Symbol Usage

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

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

NOTICEIndicates statements not related to personal injury.

Indicates special instructions.

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

1-2. Arc Welding Hazards

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

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

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

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The input

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

Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats

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

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

Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on

unit.

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

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

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

Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

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

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

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

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

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

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

Do not touch electrode holders connected to two welding ma-chines at the same time since double open-circuit voltage will bepresent.

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

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

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

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

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

SIGNIFICANT DC VOLTAGE exists in inverter-type

welding power sources after removal of inputpower. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

HOT PARTS can cause severe burns.

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

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

wear heavy, insulated welding gloves andclothing to prevent burns.


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

FUMES AND GASES can be hazardous.

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

If inside, ventilate the area and/or use local forced ventilation at thearc to remove welding fumes and gases.

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

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

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

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

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

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

ARC RAYS can burn eyes and skin.

Wear an approved welding helmet fitted with a proper shade of fil-ter lenses to protect your face and eyes when welding or watching(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

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

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

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

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

WELDING can cause fire or explosion.

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

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

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

Watch for fire, and keep a fire extinguisher nearby.

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

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

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

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

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

contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

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

FLYING METAL or DIRT can injure eyes.

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

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

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

MAGNETIC FIELDS can affect ImplantedMedical Devices.

Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

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

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing. Wear approved ear protection if noise level is

high.

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

CYLINDERS can explode if damaged.

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

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

Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in

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

ber of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.


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

FIRE OR EXPLOSION hazard.

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

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

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

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift andsupport unit.

If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before

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

FLYING SPARKS can cause injury.

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

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

Sparks can cause fires keep flammables away.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handlingboards or parts.

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

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

Do not press gun trigger until instructed to doso.

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

MOVING PARTS can cause injury.

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

closed and securely in place.

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

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

READ INSTRUCTIONS.

Read Owners Manual before using or servic-ing unit.

Use only genuine replacement parts from themanufacturer.

H.F. RADIATION can cause interference.

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

communications equipment. Have only qualified persons familiar with

electronic equipment perform this installation. The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-tion.

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

Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

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

Be sure all equipment in the welding area iselectromagnetically compatible.

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

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

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

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.


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1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

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

For Diesel Engines:

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

defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping,American Welding Society StandardAWS F4.1, from Global Engineering Documents (phone:1-877-413-5184,website: www.global.ihs.com).

National Electrical Code,NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:617-770-3000, website: www.nfpa.org and www. sparky.org).

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

from Compressed Gas Association, 4221 Walney Road, 5th Floor,Chanti lly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting,CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 5060 Mississauga,

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto416-747-4044, website: www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion,ANSI Standard Z87.1, from American National Standards Institute,25 West 43rd Street, New York, NY 100368002 (phone:212-642-4900, website: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork,NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-site: www.nfpa.org.OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 Regional Officesphone forRegion 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic Fields

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

committees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.

To reduce magnetic fields in the workplace, use the followingprocedures:

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

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

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

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

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

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


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SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

fre_som_2007047

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

2-1. Symboles utiliss

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

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

NOTEIndique des dclarations pas en relation avec des blessurespersonnelles.

Indique des instructions spcifiques.

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

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce ma-

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

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

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

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr la

sortie. Le circuit dalimentation et les circuits internes de la machinesont galement sous tension lorsque lalimentation est sur Marche.Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalliques en contactavec le fil sont sous tension lectrique. Un quipement install ou mis la terre de manire incorrecte ou impropre constitue un danger.

Ne pas toucher aux pices lectriques sous tension.

Porter des gants isolants et des vtements de protection secs etsans trous.

Sisoler de la pice couper et du sol en utilisant des housses oudes tapis assez grands afin dviter tout contact physique avec lapice couper ou le sol.

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

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

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

Dautres consignes de scurit sont ncessaires dans les condi-tions suivantes : risques lectriques dans un environnementhumide ou si lon porte des vtements mouills ; sur des structuresmtalliques telles que sols, grilles ou chafaudages ; en positioncoince comme assise, genoux ou couche ; ou sil y a un risquelev de contact invitable ou accidentel avec la pice souder oule sol. Dans ces conditions, utiliser les quipements suivants,dans lordre indiqu : 1) un poste souder DC tension constante

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

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

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

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

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

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

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

Lquipement doit tre hors tension lorsquil nest pas utilis. Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

sante ou mal pisss. Ne pas enrouler les cbles autour du corps.

Si la pice soude doit tre mise la terre, le faire directementavec un cble distinct.

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

Ne pas toucher des porte lectrodes connects deux machines

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

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

Porter un harnais de scurit si lon doit travailler au-dessus du sol.

Sassurer que tous les panneaux et couvercles sont correctementen place.

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

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

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


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Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur quand on acoup lalimentation. Arrter les convertisseurs, dbrancher le courant lectrique et

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

DES PICES CHAUDES peuventprovoquer des brlures graves.

Ne pas toucher mains nues les partieschaudes.

Prvoir une priode de refroidissement avant dtravailler lquipement.

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

LES FUMES ET LES GAZ peuvent trdangereux.

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

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

lintrieur, ventiler la zone et/ou utiliser une ventilation force au

niveau de larc pour lvacuation des fumes et des gaz de soudage. Si la ventilation est mdiocre, porter un respirateur anti-vapeurs

approuv.

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

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

Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur et

les rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

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

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

(ultraviolets et infrarouges) susceptibles de provoquer des brlure

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

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

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

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

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

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectu sur des conteneurs ferms telque des rservoirs, tambours ou des conduites peprovoquer leur clatement. Des tincelles peuve

tre projetes de larc de soudure. La projection dtincelles, des picechaudes et des quipements chauds peut provoquer des incendiesdes brlures. Le contact accidentel de llectrode avec des objetmtalliques peut provoquer des tincelles, une explosion, un surchaufement ou un incendie. Avant de commencer le soudage, vrifiersassurer que lendroit ne prsente pas de danger.

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

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

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

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

Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

ns ou se servir dun respirateur dadductiondair homologu.

LES CHAMPS MAGNETIQUES peuv-ent affecter des implants mdicaux.

Porteur de simulateur cardiaque ou autre im-plants mdicaux, rester distance.

Les porteurs dimplants doivent dabord consulter leur mdecinavant de sapprocher des oprations de soudage larc, de sou-dage par points, de gougeage, du coupage plasma ou de chauf-fage par induction.

LE BRUIT peut endommager loue.

Le bruit des processus et des quipements peutaffecter loue.

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

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

dage, les manipuler avec prcaution.

LES BOUTEILLES peuvent exploser

si elles sont endommages.

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

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

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

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

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

Ne jamais souder une bouteille pressurise risque dexplosion.

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

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

Le couvercle du dtendeur doit toujours tre en place, sauf lorsquela bouteille est utilise ou quelle est relie pour usage ultrieur.

Utiliser les quipements corrects, les bonnes procdures et suffi-samment de personnes pour soulever et dplacer les bouteilles.

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

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

Risque DINCENDIE OU DEXPLO-

SION. Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables.

Ne pas installer lappareil proximit de pro-duits inflammables.

Ne pas surcharger linstallation lectrique sassurer quelalimentationest correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LAPPAREIL peutblesser. Utiliser lanneau de levage uniquement pour

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

Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

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

LEMPLOI EXCESSIF peut SUR-CHAUFFER LQUIPEMENT. Prvoir une priode de refroidissement ; re-

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

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

LES TINCELLES VOLANTES ris-

quent de provoquer des blessures. Porter un cran facial pour protger le visage et

les yeux. Affter llectrode au tungstne uniquement l

meuleuse dote de protecteurs. Cette manuv-re est excuter dans un endroit sr lorsque lonporte lquipement homologu de protection duvisage, des mains et du corps.

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

LES CHARGES LECTROSTATI-QUES peuvent endommager les

circuits imprims. tablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistati-

ques pour stocker, dplacer ou expdier descartes de circuits imprimes.

DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.


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

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

sonnes ou toute pice mcanique en enga-geant le fil de soudage.

DES ORGANES MOBILES peuventprovoquer des blessures. Sabstenir de toucher des organes mobiles tels

que des ventilateurs. Maintenir ferms et verrouills les portes, pan-

neaux, recouvrements et dispositifs de protec-tion.

Seules des personnes qualifies sont autorises enlever lesportes, panneaux, recouvrements ou dispositifs de protectionpour lentretien.

Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS. Lisez le manuel dinstructions avant lutilisation

ou la maintenance de lappareil. Nutiliser que les pices de rechange recom-

mandes par le constructeur.

Effectuer rgulirement le contrle et lentretien de linstallation.

Maintenir soigneusement ferms les portes et les panneaux dessources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences.

Le rayonnement haute frquence (H.F.) peutprovoquer des interfrences avec les quipe-ments de radionavigation et de communica-tion, les services de scurit et les ordinateurs.

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

Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences rsultant de linstallation. Si le FCC signale des interfrences, arrter immdiatement lap-

pareil.

LE SOUDAGE LARC risque deprovoquer des interfrences.

Lnergie lectromagntique risque de provo-quer des interfrences pour lquipement lec-tronique sensible tel que les ordinateurs et l-quipement command par ordinateur tel queles robots.

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

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

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

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

En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

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

Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent descancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

Pour les moteurs essence :

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

Pour les moteurs diesel :

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


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

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1 de Global Engineering Documents (tlphone :1-877-413-5184,site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec-tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (tlphone :

617-770-3000, site Internet : www.nfpa.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, deCanadian Standards Association, 5060 Mississauga, Ontario, Canada

L4W 5NS (tlphone : 800-463-6727 ou Toronto 416-747-4044, siteInternet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-tion,ANSI Standard Z87.1, de American National Standards Institute,11 West 43rd Street, New York, NY 10036-8002 (tlphone :212-642-4900, site Internet : www.ansi.org).

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

site Internet : www.nfpa.org).OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(tlphone : 1-866-512-1800) (il y a 10 bureaux rgionauxle tlpho-ne de la rgion 5, Chicago, est 312-353-2220, site Internet :www.osha.gov).

2-6. Information EMF

Considrations sur le soudage et les effets de basse frquence et deschamps magntiques et lectriques.Le courant de soudage, pendant son passage dans les cbles de sou-dage, causera des champs lectromagntiques. Il y a eu et il y a encoreun certain souci propos de tels champs. Cependant, aprs avoir exa-

min plus de 500 tudes qui ont t faites pendant une priode derecherche de 17 ans, un comit spcial ruban bleu du NationalResearch Council a conclu : Laccumulation de preuves, suivant lejugement du comit, na pas dmontr que lexposition aux champsmagntiques et champs lectriques haute frquence reprsente unrisque la sant humaine . Toutefois, des tudes sont toujours encours et les preuves continuent tre examines. En attendant que lesconclusions finales de la recherche soient tablies, il vous seraitsouhaitable de rduire votre exposition aux champs lectromagnti-ques pendant le soudage ou le coupage.Pour rduire les champs magntiques sur le poste de travail, appliquerles procdures suivantes :

1. Garder les cbles ensemble, les torsader, les scotcher, ou lesrecouvrir dune housse.

2. Disposer les cbles dun ct et distance de loprateur.3. Ne pas courber pas et ne pas entourer pas les cbles autour de

votre corps.

4. Garder le poste de soudage et les cbles le plus loin possible devous.5. Connecter la pince sur la pice aussi prs que possible de la

soudure.

En ce qui concerne les implants mdicaux :

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


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SECTION 3 DEFINITIONS (CE Models)

3-1. Warning Label Definitions

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

1 Electric shock from welding electrodeor wiring can kill.

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

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

1.3 Disconnect input plug or power beforeworking on machine.

2 Breathing welding fumes can behazardous to your health.

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

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

or fire.3.1 Keep flammables away from welding.

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

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

3.3 Do not weld on drums or any closedcontainers.

4 Arc rays can burn eyes and injureskin.

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

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

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

1 1.1 1.2 1.3

2 2.1 2.2 2.3

3 3.1 3.2 3.3

4 4.1

5

6

S-179 310-A


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

1 Electric shock from wiring cankill.

2 Disconnect input plug orpower before working onmachine.

3 Hazardous voltage remainson input capacitors afterpower is turned off. Do nottouch fully chargedcapacitors.

4 Always wait 60 seconds afterpower is turned off beforeworking on unit, OR

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

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

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

8 Always wear long sleeves andbutton your collar whenservicing unit.

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

S-185 836

> 60 s

VV

V

1 2 3 4 5

6 7 8 9

S-179 309-A

=


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OM-2240 Page 13

3-3. Symbols And Definitions

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

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

Voltage Output Circuit Breaker Remote

Lift-Arc Start

(GTAW)

Protective Earth(Ground) Postflow Timer Preflow Timer S Seconds

On Off Positive Negative

AlternatingCurrent Gas Input Gas Output I2

Rated WeldingCurrent

X Duty Cycle Direct Current Line Connection U2Conventional Load

Voltage

U1 Primary Voltage IPDegree OfProtection I1max

Rated MaximumSupply Current I1eff

Maximum EffectiveSupply Current

U0Rated No Load

Voltage (Average)Pulse Background

Amperage Initial AmperageIncrease/Decrease

Of Quantity

Normal Trigger Op-eration (GTAW)

Two-Step TriggerOperation (GTAW)

Four-Step TriggerOperation (GTAW) Percent

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

Final Slope Final AmperagePulse Percent

On Time Initial Slope

Contactor Control(Stick) Pulser On-Off

TIG Weld AmpsAnd Peak Amps

While PulsingPulse Frequency

Background Amps Process Pulser Sequence

Output Adjust SSuitable For Areas

Of IncreasedShock Hazard


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SECTION 4 INSTALLATION4-1. Serial Number And Rating Label LocationThe serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input powerrequirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Specifications

Input Power Rated OutputWelding

AmperageRange **

Max.Open-CircuitVoltage (Uo)

Rated PeakStriking

Voltage (Up)

Amperes Input At Rated Output,50/60Hz

KVA KW

115 230 400 460

Three-Phase

Stick Process

130 A @ 25.2VDC,

60% DutyCycle

1 20080

5-1015 KV*** -

12.30.16*

7.60.24*

6.00.25*

4.80.06*

4.60.03*

Three-Phase

TIG Process

150 A @ 16VDC,

60% DutyCycle

1 200

80

5-10 15 KV***-

9.4

0.16*

6.0

0.24*

4.7

0.25*

3.8

0.06*

3.6

0.03*

Three-PhaseStick Process

200 A @ 28VDC, 20%Duty Cycle

1 200

80

5-10 15 KV***20.8

0.16*

13.0

0.24*

10.2

0.25*

8.1

0.06*

7.8

0.03*

Three-PhaseTIG Process

200 A @ 18VDC, 20%Duty Cycle

1 200

80

5-10 15 KV***13.7

0.16*

8.7

0.24*

6.9

0.25*

5.5

0.06*

5.2

0.03*

Single-Phase

Stick Process

130 A @ 25.2VDC,

60% DutyCycle

1 200

80

5-10 15 KV*** -20.00.23* -

10.0

.25*4.7

0.05*4.7

0.02*

Single-Phase

TIG Process

150 A @ 16VDC,

60% DutyCycle

1 200

80

5-10 15 KV***-

15.8

0.23*-

7.9

.25*

3.6

0.05*

3.6

0.02*

Single-PhaseStick Process

100 A @ 24VDC,60% Duty

Cycle

1 20080

5-10 15 KV***31.30.42* - - -

3.60.05*

3.60.03*

Single-Phase

TIG Process

140 A @ 15.6VDC,

40% DutyCycle

1 200 80

5-10

15 KV*** 31.00.42* - - -3.6

0.05*

3.5

0.03*

Single-Phase

Stick Process

90 A @ 23.6VDC,

100% DutyCycle

1 200

80

5-10 15 KV***27.60.42* - - -

3.2

0.05*

3.2

0.03*

Single-Phase

TIG Process

100 A @ 14VDC,

100% DutyCycle

1 200

80

5-10 15 KV***

20.7

0.42* - - -

2.3

0.05*

2.3

0.03*

*While idling

** Welding range for AC output is 5200 amperes

*** Arc starting device is designed for manual guided operations.

Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected.

Normal open-circuit voltage (80 volts) is present while in Stick with normal open-circuit voltage selected.

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

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


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4-3. DC Volt-Ampere Curves

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

210 168-A

3 Phase Voltage Input; DC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

V

olts

Dig Max.Stick/TIG Min.

Stick Max.

TIG Max.

230VAC Single Phase Input; DC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min. DIG Max.

115VAC Input; DC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min.DIG Max.

*

*

*

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


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OM-2240 Page 16

4-4. AC Volt-Ampere Curves

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

210 168

115VAC Input; AC Output

0

20

40

6080

100

120

140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min.

230VAC Single Phase Input; AC Output

0

20

40

60

80

100

120140

0 50 100 150 200 250Amperes

Volts

Stick Max.

TIG Max.

Stick/TIG Min.

3 Phase Voltage Input; AC Output

0

20

40

60

80

100

120

140

0 50 100 150 200 250Amperes

V

olts

Stick/TIG Min.

Stick Max.

TIG Max.

*

*

*

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


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OM-2240 Page 17

4-5. Duty Cycle And Overheating

210 167

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

If unit overheats, output stops, aHelp message is displayed (seeSection 7-3), and cooling fan runs.Wait fifteen minutes for unit to cool.Reduce amperage or voltage, orduty cycle before welding.

NOTICE

Exceeding duty cyclecan damage unit or gun and voidwarranty.

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

6 Minutes Welding 4 Minutes Resting

Overheating

0

15

A or V

ORReduce Duty CycleMinutes

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

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

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

0

50

100

150

200

250

10 100

% DUTY CYCLE

OUTPUTAMPERES

STICK

TIGTIG (115V INPUT)

STICK (115V INPUT)

20 30 40 50 60 70 80 90

Continuous Welding

100%dutycycle


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OM-2240 Page 18

4-6. Selecting A Location

1 Line Disconnect Device

Locate unit near correct inputpower supply.

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

Location And Air flow1

18 in (460 mm)Clearance

18 in (460 mm)Clearance

803 428-A

21 in(533 mm)

13-3/8 in(333 mm)

7-9/16 in(192 mm)

Dimensions And Weight

48.5 lb (22.0 kg)


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OM-2240 Page 19

4-7. Weld Output Terminals And Selecting Cable Sizes*

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

! Turn off power beforeconnecting to weldoutput terminals.

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

100 ft (30 m) Or Less 150 ft(45 m)200 ft(60 m)

WeldingAmperes***

10 60%DutyCycle

60 100%DutyCycle

10 100% Duty Cycle

Output Receptacles

+

100 4 (20) 4 (20) 4 (20) 3 (30)

150 3 (30) 3 (30) 2 (35) 1 (50)

200 3 (30) 2 (35) 1 (50) 1/0 (60)

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

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

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

4-8. Remote 14 Receptacle Information

803 428-A

A JB K I

C L N H

D M GE F

Socket* Socket Information

15 VOLTS DC

OUTPUTCONTACTOR

A Contactor control +15 volts DC.

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

REMOTEOUTPUT

CONTROL

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

D Remote control circuit common.

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

A/VAMPERAGEVOLTAGE

F Current feedback; +1 volt DC per 100 amperes.

H Voltage feedback; +1 volt DC per 10 volts output.

GND G +15 volts DC GND

CHASSIS K Chassis common.

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

* The remaining socketes are not used.


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4-9. Gas Connections

802 452

1 Gas Fitting

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

2 Cylinder Valve

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

3 Regulator/Flowmeter4 Flow Adjust

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

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

Tools Needed:

3 24

1

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

4-10. TIG HF Impulse/ Lift-ArcConnections

803 430-a

! Turn off power before mak-ing connections.

1 Electrode Weld OutputTerminal

Connect TIG torch to weld outputterminal labeled Electrode.

2 Gas Out Connection

Connect torch gas hose to gas outfitting.

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

4 Remote 14 Receptacle

Connect desired remote control toRemote 14 receptacle.

5 Gas In Connection

Connect gas hose from gas supplyto gas in fitting.

Tools Needed:

11/16 in, (21 mm)

5

3

4

21


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4-11. Stick Connections

803 429-a

! Turn off power before mak-ing connections.

1 Electrode Weld OutputTerminal

Connect electrode holder to weldoutput terminal labeled Electrode.

2 Work Weld Output Terminal

Connect work lead to weld output

terminal labeled Work.3 Remote 14 Receptacle

If desired, connect remote controlto Remote 14 receptacle (see Sec-tion 4-8).

1

2

3


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4-12. TIGRunner Connections

Cart and cooler are optional equip-ment.

1 Gas Cylinder2 Chains

Secure gas cylinder to cart withchains.

Connect gas hose to welding powersource (see Section4-9).

Connect work lead and torch towelding power source (see Section4-10).

3 Water-Out (To Torch)Connection

Connect torch water-in (blue) hoseto welding power source water-outconnection.

4 Water-In (From Torch)Connection

Connect torch water-out (red) hoseto welding power source water-inconnection.

5 115 Or 230 Volt AC GroundedReceptacle (Depending On

Model)For 115 volt models, an individualbranch circuit capable of carrying15 amperes and protected by fusesor circuit breakers is recom-mended. Recommended fuse orcircuit breaker size is 15 amperes.For 230 volt models, an individualbranch circuit capable of carrying10 amperes and protected by fusesor circuit breakers is recom-mended. Recommended fuse orcircuit breaker size is 10 amperes.

6 Power Cord

NOTICEDo not cut plug from 115volt cord and attempt to rewire for

230 volts, or do not cut plug from230 volt cord and attempt to rewirefor 115 volts.

1

Low Conductivity CoolantNo. 043 810**;Distilled Or Deionized WaterOK Above 32 F (0C)

GTAW Or Where

HF* Is Used

Application

*HF: High Frequency Current

**Coolant 043 810, a 50/50 solution, protect to -37 F (-38C) and resist algae growth.

Coolant

805 338-A

Tools Needed:

11/16 in, (21 mm for CE units)

NOTICE Use of any coolant other than those listed in the table voids the warrantyon any parts that come in contact with the coolant (pump, radiator, etc.).

2

3

4

5

6


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OM-2240 Page 23

4-13. Electrical Service Guide

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

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

Input Voltage

Single-Phase,100% Duty

Cycle

Single-Phase,60% Duty

Cycle

Three-Phase, 60% DutyCycle

115 230 230 400 460

Input Amperes At Rated Output 28 20 12.3 7.6 6.0

Max Recommended Standard Fuse Rating In Amperes 1

Time Delay 2 30 25 15 8 6

Normal Operating 3 40 30 20 10 10

Min Input Conductor Size In AWG 4 10 12 14 14 14

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

308(94)

407(124)

Min Grounding Conductor Size In AWG 4 10 12 14 14 14

Reference: 2005 National Electrical Code (NEC)1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.2 Time-Delay fuses are UL class RK5 .3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

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

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


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OM-2240 Page 24

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

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

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

! Always connect green or green/yellow conductor to supply

grounding terminal first, and neverto a line terminal.

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

For Three-Phase Operation

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

the OFF position)3 Green Or Green/Yellow Grounding

Conductor4 Disconnect Device Grounding

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

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

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

7 Overcurrent Protection

Select type and size of overcurrent protec-tion using Section 4-13(fused disconnectswitch shown).

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

= GND/PE Earth Ground

L1

2

1

L2

L3

3

3

4

5

6

7

Tools Needed:

4-14. Connecting Three-Phase Input Power


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OM-2240 Page 25

4-15. Connecting Single-Phase Input Power

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

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

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

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

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

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

1 Black And White Input Conductor(L1 And L2)

2 Red Input Conductor3 Green Or Green/Yellow Grounding

Conductor4 Insulation Sleeving

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

the OFF position)8 Disconnect Device Grounding

Terminal9 Disconnect Device Line Terminals

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

Connect input conductors L1 and L2 todisconnect device line terminals.

10 Overcurrent ProtectionSelect type and size of overcurrent protec-tion using Section 4-13(fused disconnectswitch shown).

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

1

6

54

2

7

6

L1L2

1

=GND/PE Earth Ground

3

3

1

8

9

10

Tools Needed:


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OM-2240 Page 26

SECTION 5 OPERATION

207 694-A / 802 452

12

For all front panel switch pad controls:press switch pad to turn on light and en-able function.

Green on nameplate indicates a TIG func-tion, Gray indicates a Stick function.

1 Encoder Control

Use encoder control in conjunction with appli-cable front panel function switch pads tochange values for that function. See Section5-2.2 Ammeter And Parameter Display

See Section 5-4.

3 Voltmeter

See Section 5-5.

4 Polarity Control

See Section 5-6.

5 Process Controls

See Section 5-8.

6 Output Controls

See Section 5-9.

7 Pulser Controls (DX AndLX Models)

See Section 5-10.

8 Sequencer Controls (DX, LXAnd All CE Models)

See Section 5-11.

9 Adjust Controls

See Section 5-12.

10 AC Waveshape Control

See Section 5-13.

11 Amperage And Spot Time ControlFor Amperage control, see Section 5-3.

For Spot Time control, see Section 5-14.

12 Power Switch

Use switch to turn unit On/Off.

5-1. Controls

123

4 5

11

86 7 9 10