Miller ADI 253 User manual

Miller
The
Power
fBlue.
OM-2217
April
1997
En.
w/SeriaI
Number KH384382
Processes
TIG
(GTAW)
Welding
Stick
(SMAW) Welding
0
Description
Arc
Welding
Power Source
~
fllli~Gk~1
7J~
TM
Visit
our
website
at
www.m~e~weIds.com
OWNERS
MANUAL

Thank
you
and
congratulations
on
choosing
Miller. Now
you
can
get
the
job
done and
get
it done
right.
We
know
you
dont have
time
to
do it
any
other
way.
Thats
why
when Neils
Miller first
started
building
arc
welders in
1929,
he
made
sure
his
products
offered
long-lasting
value and
superior
quality.
Like
you,
his
customers
couldnt 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.
Theyre just
as
conmiitted
to
providing
equipment
and service
that
meets
the
high
standards of
quality
and value
established
in
1929.
This Owners Manual is
designed
to
help
you
get
the
most
out
of
your
Miller
products.
Please take time
to
read the
Safety precautions.
They
will
help
you
protect
yourself against
potential
hazards
on
the worksite.
Weve
made
installation and
operation quick
and
easy.
With Miller
you
can
count
on
years
of reliable
service with
proper
maintenance.
And
if for
______________
some reason
the unit needs
repair,
theres
a
Troubleshooting
section
that
will
help
you
figure
out
what the
problem
is.
The
parts
list
will
then
help
you
to
decide
which
exact
part
you may
need
to
fix
the
problem.
Warranty
and
service information for
your
particular
model
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.
From
to
You
11~iIJIIIII
Ir
REGISTERED
QUALITY
SYSTEM
Miller is
the first
weldiNg
equipment
manufacturer
in
the U.S.A.
to
be
registered
to
the
ISO 9001
Quality
System
Standard.
~?ft~JR~ft1ll1?
Working
as
hard
as
you
do

every power
source
from
Miller Is backed
by
the
most
hassle-free
warranty
in
the
business.
f//A
MHIer
The
Power
?fBlue.

TM
Description
The ADl~
253
combines the
advantages
of inverter
based
power
with
the built-in features and
technology
of
a
high-end
TIG
machine.
At
only
90 lbs.
(40.7 Kg),
the
ADI
253
gives
you
the
portability
to
easily
take it
anywhere
its
needed.
Plus,
it
can
operate
oft either
single-
or
three-phase
power.
The
unique
AutoLirikfi
feature
automatically
links
the
power
source
to
the
primary input voltage.
The
AOl
253 is
available
for
superior
AC/DC
TIG
(GTAW)
and
Stick
(SMAW)
welding.

300
amps
maximum
output,
250
amps
at
40%
duty
cycle

Dig/Arc
force
control

NEMA Class
1
rating

HF
Lift ArcTM
starting
for AC and
DC
TIG
(GTAW)

Fan-On-Demand~
operates
the
cooling
system
only
when
needed

lOft(3m)powercord

MILLERS
True Bluefi
3
year
warranty

Product features
and
specifications
are
subject
to
change
without
notice
Processes
TIG
(GTAW)
Welding
Call
1
-800-4-A-MILLER
for
your
local
Miller
distributor.
Your distributor
gives
you
Service
You
always
get
the
fast,
reliable
response you
need.
Most
replacement
parts
can
be in
your
hands
in 24
hours.
Support
Need
fast
answers
to
the
tough
welding
questions?
Contact
your
distributor.
The
expertise
of
the
distributor
and
Miller is
there
to
help
you,
every
step
of
the
way.
Stick
(SMAW)
Welding
The
following
terms
are
used
interchangeably
throughout
this
manual:
TIG
= GTAW
Stick
=
SMAW
Miller
offers
a
Technical
Manual
15
which
provides
more
detailed
se,vice
and
parts
information
for
your
unit.
To
obtain
a
Technical
Manual,
contact
your
local
distributo,
Your
distributor
can
also
supply
you
~wTh
Welding
Process
Manuals
such
as
SMAW,
GTAW,
GMAW,
and
GMAW-P
For
practical
information
on
weld
ing,
process
applications,
and
Miller
products,
visit
our
website
at
Features
1
Table
of
Contents
Section
.
::
Page
1.
Safety
Precautions
2.
Introduction
9
3.
Operation
4.
Maintenance
and
Troubleshooting
18
5.
Electrical
Diagram
22
6.
Parts
List
.24
Options
and
Accessories
Warranty
www.n~erwe~Is.com

1.
Safety
Precautions

Read
Before
Using
111
SymbOl
Usage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special safety
message.
~
Means
Note;
not
safety
related.
1
2
Arc
Welding
Hazards
A
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
1.4.
Read and
follow all
Safety
Standards.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A During operation, keep
everybody,
especially
children,
away.
Touching
live
electrical
parts
can
cause
fatal
shocks
or severe
bums.
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.

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
work
or
ground.

Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there 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.

Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout input
power
according
to
OSFIA
29
CFR 191 0.147
(see
Safety Standards).

Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and local
codes.

Always verify
the
supply
ground

check and
be
sure
that
input
power
cord
ground
wire is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properiy
grounded
receptacle
outlet.

When
making
input
connections,
attach
proper
grounding
conductor
first

double-check
connections.

Frequently inspect
input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.

Turn oft all
equipment
when
not
in
use.

Do
not
use
worn,
damaged,
undersized,
or
pooriy spliced
cables.
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.

Do
not
drape
cables
over
your
body.

If
earth
grounding
of the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work cable.

Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another electrode
from
a
difterent
machine.

Use
only
well-maintained
equipment.
Repairor
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.

Wear
a
safety
harness
if
working
above
floor
level.

Keep
all
panels
and
covers
securely
in
place.

Clamp
work
cable with
good
metal-to-metal
contact
to
workpiece
or
worktable
as near
the
weld
as
practical.

Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact with
any
metal
object.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.

Turn Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
FUMES
ANDGASES
can
be
hazardous.

Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be hazardous
to
your
health.

Keep
your
head
out
of the
fumes. Do
not
breathe
the
fumes.

If
inside,
ventilate the
area
and/or
use
exhaust at
the
arc
to
remove
welding
fumes
and
gases.

If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.

Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers instructions for
metals, consumables,
coatings,
cleaners,
and
degreasers.

Work in
a
confined
space
only
if
it is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watch-
person
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower the
oxygen
level
causing injury
or
death.
Be
sure
the
breathing
air is
safe.

Do
not
weld
in locations
near
degreasing, cleaning,
or
spraying
operations.
The heat
and
rays
of
the
arc
cart
react
with
vapors
to
form
highly
toxic
and
irritating
gases.

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
oft
toxic
fumes
if
welded.
OM-2217
-
Date,
safety_corn
4197
ELECTRIC
SHOCK
can
kill.
OM-221
7
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
bum
eyes
and skin.
Sparks
fly
oft from
the
weld.

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).

Wear
approved
safety glasses
with
side shields
under
your
helmet.

Use
protective
screens
or
barriers
to
protect
others from
flash and
glare;
wam
others
not
to
watch
the
arc.

Wear
protective
clothing
made
from
durable,
flame-resistant
matenal
(leather
and
wool)
and
foot
protection.
WELDING
can
causefireorexplosion.
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.

Protect
yourself
and others from
flying
sparks
and
hot
metal.

Do
not
weld
where
flying
sparks
can
strike flammable material.

Remove
all
flammables
within 35 ft
(10.7
m)
of
the
welding
arc.
If
this is
not
possible,
tightly
cover
them
with
approved
covers.

Be alert that
welding sparks
and hot materials
from
welding
can
easily
go
through
small cracks and
openings
to
adjacent
areas.

Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.

Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can cause
fire
on
the hidden side.

Do
not
weld
on
closed containers such
as
tanks, drums,
or
pipes,
unless
they
are
properly prepared
according
to
AWS
F4.i
(see
Safety Standards).

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.

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.
FLYING METALcan
injure
eyes.

Welding, chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal. As
welds
cool,
they
can
throw
oft
slag.

Wear
approved
safety
glasses
with
side
shields
even
under
your
welding
helmet.
BUILDUP OF
GAS
can
injure
or
kill

Shut off
shielding
gas
supply
when
not
in
use.

Always
ventilate
confined
spaces
or
use
approved air-supplied respirator.
HOT
PARTS
can
causesevere
burns..

Do
not
touch hot
parts
bare
handed.

Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affect
pacemakers..

Pacemaker
wearers
keep
away.

Wearers
should consult their
doctor
before
going
near arc
welding,
gouging,
or
spot
welding
operations.
NOISE
can
damage hearing.
Noise
from
some
processes
or
equipment
can
damage
hearing.

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.

Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.

Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
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
fittings designed
for
the
specific application;
maintain them
and
associated
parts
in
good
condition.

Turn
face
away
from
valve
outlet when
opening cylinder
valve.

Keep
protective
cap
in
place
overvalve
except
when
cylinder
is
in
use or
connected
for
use.

Read and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and CGA
publication
P-i
listed
in
Safety
Standards.
2
OM-22i
7

-
FIRE
OR
EXPLOSION
hazard.

Do
not
install
or
place
unit
on,
over,
or
near
A
combustible surfaces.

Do
not
install
unit
near
flammables.

Do
not
overload
building
winng

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
running
gear, gas
cylinders,
or
any
other
accessories.

Use
equipment
of
adequate
capacity
to
lift and
support
unit.

If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond opposite
side
of
unit.
OVERUSE
can cause
OVERHEATING

Allow
cooling
period;
follow
rated
duty
cycle.

Reduce
current
or
reduce
duty cycle
before
starting
to
weld
again.

Do
not
block
or
filter
airflow
to
unit.
STATIC
(ESD~
can
damage
PC
boards.

Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.

Use
proper
static-proof
bags
and boxes
to
store,
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
do
so.

Do
not
point
gun
toward
any part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
: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
Superinten
dent
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,
Batteryrnarci,
Park,
Quincy,
MA 02269.
MOVING
PARTS
can
cause
injury.

Keep
away
from
moving
parts
such
as
fans.

Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
H.F.
RADIATION
can cause
interference.

High-frequency (H.F.)
can
interfere
with
radio
navigation, 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
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.
ARC WELDING
can cause
interference.

Electromagnetic
energy
can
interfere
with
sensitive electronic
equipment
such
as
computers
and
computer-driven equipment
such
as
robots.

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
elec
tronic
equipment.

Be
sure
this
welding
machine is
installed
and
grounded
according
to
this manual.

If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235 Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA 22202.
Code for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard, Rexdale, Ontario,
Canada
M9W
1
R3.
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
51
B,
from National
Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1 3
Additional
Symbols
for
Installation,
Operation,
and Maintenance
OM-221
7
3

1
5
EMF Information
Considerations
About
Welding
And The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General Conclusions Section of
the U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects of
Power
Frequency
Electric &
Magnetic
Fields

Background
Pape,
OTA-BP-E-53
(Washington,
DC:
U.S. Government
Printing
Office,
May
1989):.
. .
there is
now
a
very
large
volume
of scientific
findings
based
on
experiments
at
the cellular
level
and from studies
with animals and
people
which
clearly
establish that low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of this work
is of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
in
terpret
the
evidence
in
a
single
coherent framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables close
together by twisting
or
taping
them.
2.
Arrange
cables
to
one
side and
away
from
the
operator.
3. Do
not
coil
or
drape
cables
around the
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
possible.
About Pacemakers:
The
above
procedures
are
also recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
4
OM-2217

1.
Consignes
do
sØcuritØ

lire
avant
utilisatioN
:1.1
Signification
des:symbOles
a
Signifie
Mise
en
garde! Soyez vigilant!
Cette
procedure
prØsente
des
risques
de
danger!
Ceux-ci
sont
identifies
par
des
symboles
adjacents
aux
directives.
A
Identifie
un
message
de
sØcuritØ
particulier.
~
Signifie
NOTA
nestpas
relatif a
Ia
sØcuritO.
12
Dangersrelatifsau
Soudage
a
Iarc
A
Lea
symboles
prØsentØs
ci-aprŁs
sont
utilisØs
tout
au
long
du
present
manuel
pour
attirer
votre
attention
et
identifier
les
risques
de
danger.
Lorsque
vous
voyez
un
symbole,
soyez
vigilant
et
suivez les directives
mentionnØes
atm
dØviter
tout
danger.
Les
consignes
de
sØcuritØ
prØsentees ci-aprŁs
ne
font
que
rØsumer
linformation
contenue
dans
lea
normes
de
sØcuritØ
ØnumØrØes
a
Ia
section
1-5.
Veuillez lire
et
respecter
toutes ces
normes
de
sØcuritØ.
A
Linstallation,
lutilisation,
lentretien
et
les
reparations
ne
doi
vent
Œtre confiØs
qua
des
personnes
qualifiØes.
A
Au
cours
de
lutilisation,
tenirtoute
personne
a
lØcart
et
plus
par
ticuliŁrement
les
enfants.
UNCHOC
ELECTRIQUE
peut
tuer.
Un
simple
contact
avec
des
piŁces Łlectrtques
peut
provoquer
une
electrocution
ou
des
blessures
graves.
LØlectrode
et
le circuit de
soudage
sont
sous
tension
des
que
lappareil
est
sur
ON.
Le
circuit
dentrØe et
les
circuits
intemes
de
Iappareil
sont
egalement
sous
tension
ace moment-l.
En
soudage semi-automatique
ou
automatique,
le
fil,
le
dØvidoir,
le
logement
des
galets
dentraInement
et
es
piŁces
metalliques
en
contact
avec
le
fil
de
soudage
sont
sous
tension.
Des
matØnels mal
installØs
ou
ma! mis
a Ia
terre
presentent
un
danger.

Ne
jamais
toucher
es
piŁces electnques
sous
tension.

Porter
des
gants
et
des
vØtements
de
protection
secs
ne
comportant
pas
de
trous.

Sisoler
de Ia
piŁce
et
de
Ia
terre
au
moyen
de
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empecher
le
contact phy
sique
Øventuel
avec
a
piŁce
ou
Ia
terre.

Ne
passe
servir
do
source
electrique
courant
electnque
dans les
zones
humides,
dans
les endroits
confines
ou
l oU
on
risque
de
tomber.

Se
servir
dune
source
Ølectrique
courant
Ølectnque
UNIQUEMENT
si le
procØdØ
do
soudage
le demande.

Si Iutilisation
dune
source
electrique
courant
electnque
savŁre
neces
saire,
se servir
de Ia
fonction
de
telØcommande
Si
Iappareil
en
est
equipe.

Couperlalimentation
ou
arrØter
!e
moteuravant
de
procedera
instal
lation,
a Ia
reparation
ou
a lentretien de
lappareil.
DŁverrouiller
lalimentation
selon
Ia
norme
OSHA
29
CFR
191
0.147
(voir
norrnes
de
sØcunte).

Installeret
mettre
a
laterre
correctement cot
apparel!
conformØment a
son
manuel
dutilisation
et
aux
codes
nationaux,
provinciaux
et
municipaux.

Toujours
verifier Ia
terre
du cordon dalimentation

Verifier
et
sassu
rer
que
le
fil
de
terre
du cordon
dalimentation
est
bien
raccordØ a Ia
borne
de
terre
du sectionneurou
que
Ia fiche du
cordon
esi
raccordØe
a
une
pnse
correctement
mise a Ia
terre.

En
effectuant les raccordements
dentrØe fixer
dabord le
conducteur
de
mise a Ia
terre
approprie
et
contre-vØrifier
les connexions.

Verifier
frequemment
le cordon dalimentation
pour
voir sil
nest
pas
endommage
ou
dØnudØ

remplacer
le
cordon
immØdiatement
si!
est
endommagŁ

un
cable dØnudØ
pout
provoquer
une
electrocution.

Mettre
lappareil
hors
tension
quand
on
ne
lutilise
pas.

Ne
pas
utiliser
des
cables
uses,
endommagØs,
de
grosseur
insuffi
sante
ou
mal
ØpissØs.

Ne
pas
enrouler
les
cables
autour
du
corps.

Si Ia
piŁce
soudØe doit Øtre mise
a
laterre,
le
faire
directementavec
un
cable distinct

ne
pas
utiliser
le
connecteur cie
piŁce
ou
le
cable de
retour.

Ne
pas
toucher
lØ!ectrode
quand
on
est
en contact avec
Ia
piŁce,
Ia
terre
ou une
electrode
provenant
dune
autre
machine.
ri~~d
Ce
groupe
de
symboles
signifie
Mise
en
garde!
Soyez
vigilant
Ill
y
a
des
risques
de
danger
relies
aux
CHOCS
ELECTRIQUES,
aux
PIECES EN
MOUVEMENTetaux
PIECES
CHAUDES.
Reportez-vousauxsymboles
et
aux
directives
ci-dessous
afin de
connaltre
es mesures
a
prendre
pour
Øviter
tout
danger.

Nutiliser
quun
materiel
en
bon
Øtat.
Reparer
ou
remplacer
sur-le
champ
les
piŁces
endommagees.
Entretenir
lappareil
conforniØment
ace
manuel.

Porter
un
hamais
de
sŁcuntŁ
quand
on
travaille
en
hauteur.

Maintenir
solidement
en
place
tous
les
panneaux
et
capots.

Fixer le cable
de
retour
de
faon
a obtenir
un
bon
contact
mŁtal-mŁtal
avec
Ia
piŁce
a souderou
latable do
travail,
le
plus
prŁs possible
de
Ia
soudure.

Rangeret
isolercorrectement
Ia
pince
de
masse
aprŁs
utilisation
pour
Łviter le
contact
avec
des
objets
relies
a
Ia
masse.
Ily
a
DU
COURANT
CONTINU
IMPORTANT dans
les
convertisseurs
aprŁs
Ia
suppression
de
Ialimenta
tion
electrique.

ArrØter
les
convertisseurs,
debrancher
le
courant
Ølectnque,
et
dØ
charger
es
condensateurs
dalimentation
selon
es
instructions
indiquees
dans Ia
partie
entretien
avant
do
toucher
les
piŁces.
LES
FUMEES
El
LES
GAZpeuvent~~
ºtre
dangereux~
:
:.:..
Le
soudage
genere
des
fumŁes
et
des
gaz.
Leur
inhalation
pout
Øtre
dangereux
pour
votre
sante.

Eloigner
voire
tŒte des
fumØes.
Ne
pas
respirer
les
fumØes.

A
IintØneur,
ventiler
Ia
zone
etlou
utiliser
un
Łchappemenl
au
ni
veau
de
arc
pour
lŁvacuation
des
fumŁes
et
des
gaz
de
soudage.

Si
Ia
ventilation
est
insuffisante,
utiliser
un
respirateur
a
alimenta
tion
dair
homologue.

Lire
es
specifications
de
sØcuntØ
des
matØnaux
(MSDS5)
et
los ins
tructions
du fabncant
concemant
los
mØtaux,
les
consommables,
les
revØtements,
les
nettoyants
et
les
degraisseurs.

Travailler
dans
un
espace
ferrnØ seulement siI
est
bien
ventilØ
ou
en
portant
un
respirateur
alimentation
dair.
Demandertoujours
a
un
surveillant
dQment
formŁ dose
tenir
a
prvximitØ.
Des
fumØes
et
des
gaz
de
soudage
peuvent
dep!acer
lair
et
abaisser
le niveau
doxygene
provoquant
des
blessures
ou
des
accidents
mortels.
Sassurer
que
lair de
respiration
no
presente
aucun
danger.

Ne
pas
souder
dans des
endroits
situŁs a
proximite doperations
de
degraissage,
de
nettoyage
ou
de
pu!vŁnsation.
La
chaleur
et
les
rayons
do
Iarc
peuvent
rØagir
en
presence
de
vapeurs
et
former
des
gaz
hautement
toxiques
et
irritants.

Ne
pas
souder
des
mØtaux
munis dun
revØtement,
tels
quo
lacier
gatvanise,
plaque
en
p10mb
ou au
cadmium
a moms
quo
le
revØte
meni
nait
ete
enlevØ
dans
Ia
zone
de
soudure,
que
lendroit
soit
bien
ventilØ,
et
si
nŁcessaire,
en
portant
un
respirateur
a a!imenta
tion
dair. Las
revØtements
et tous
les
mØtaux renfermant
ces
Øle
ments
peuvent
degager
des
fumØes
toxiques
en
cas
do
soudage.
5
OM-221
7

LES
RAVONS
DE LARC
peuvent
pro
I:
voquer
des
brUlures
dans
lea
yeux
et
sur
Ia
peau
Le
rayonnement
de larc
du
procØdØ
de
soudage
gØnŁre
des
rayons
visibles
et
invisibles
intenses
(ultraviolets
et
infrarouges)
susceptibles
de
provoquer
des brUlures
dans les
yeux
et
sur
Ia
peau.
Des
etincelles
sont
projetees
pendant
le
soudage.

Porter
un
casque
de
soudage
muni dun ecran
de
filtre
appropriO
pour
proteger
votre
visage
et
vos
yeux
pendant
le
soudage
ou
pour
regar
der
(voirANSi
Z49.1
et
Z87.1
Ønumere
dans
les
nornies
de
securite).

Porter des
protections
approuves
pour
es
oreilles si
le
niveau sondre
est
trop
Øleve.

Utiliser des
ecrans
ou
des
barriŁres
pour
proteger
des tiers de
leclair
et
de
leblouissement;
demander
aux autres
personnes
de
ne
pas
re
garder
arc.

Porter des
vØtements de
protection
constitue dans
une
matiere dura
ble,
resistant
au
feu
(cuir
ou
lame)
et
une
protection
des
pieds.
m
5~5J
LE SOUDAGE
peut
prvoquer
~
incendie
ou
une
explosion.
Le
soudage
effectue
sur
des
conteneurs
fermes
tels
que
des
reservoirs,
tambours
ou
des
conduites
peut
provoquerleureclatement.
Des
Otincelles
peuvent
ºtre
projetees
de
larc de
soudure. La
projection
detincel
les,
des
piŁces
chaudes
et
des
Øquipements
chauds
peut
provoquerdes
incendies
et
des
brUlures.
Le
contact
accidentel
de
electrode
avec
des
objets
mØtalliques
peut
provoquer
des
etincelles,
une
explosion,
un
surchauffement
ou
un
incendie.
Avant
de
commencer
le
soudage,
verifier
et
sassurer
que
lendroit
ne
presente
pas de
danger.

Se
protØger
et
dautres
personnes de
Ia
projection
detincelles
et
de
metal chaud.

Ne
pas
souder dans
un
endroit
l
o
des
Øtincelles
peuvent
tomber
sur
des substances
inflammables.

DOplacertoutes
les substances inflammables a
une
distance
de
10,7
m
de lam de
soudage.
En
cas
dimpossibilite
les
recouvrirsoigneuse
ment
avec
des
protections
homologues.

Des etincelles
et
des materlaux chauds du
soudage
peuvent
facile
ment
passer
dans dautres
zones en
traversant
de
petites
fissures
et
des
ouvertures.

Surveillertout declenchement
dincendie
et
tenirun
extincteura
proxi
mite.

Le
soudage
effectue
sur un
plafond, plancher,
paroi
ou
separation
peut
declencher
un
incendie de lautre
cOte.

Ne
pas
effectuer
le
soudage
sur
des
conteneurs
fermes
tels
que
des
reservoirs, tambours,
ou
conduites,
a
moms
quils
naient ete
prepa
rØs
correctement
conformement a AWS F4.1
(voir
les
normes
de
securite).

Brancher le cable
sur
Ia
piŁce
le
plus
pres
possible
de Ia
zone
de
sou
dage
pour
eviter
le
transport
du
courant
sur une
longue
distance
par
des
chemins
inconnus
eventuels
en
provoquant
des
flsques
dØlec
trocution
et
dincendie.

Ne
pas
utiliser le
poste
de
soudage
pour
dØgeler
des conduites
ge
lees.

En
cas
de
non
utilisation,
enlever Ia
baguette
dØlectrode
du
porte-
electrode
ou
couper
le
fil a
Ia
pointe
de
contact.

Porter des vetements
de
protection
depourvus
dhuile
tels
que
des
gants
en
cuir,
une
chemise
en
materiau
lourd,
des
pantalons
sans re
vers,
des chaussures hautes
et
un couvre
chef.

Avant de
souder,
retirertoute
substance
combustible
de
vos
poches
telles
quun
allumeur
au
butane
ou
des
allumetfes.

Le
soudage,
lecaillement,
le
passage
de
Ia
piece
a
Ia brosse
en
fil
de
fer,
et
le
meulage generent
des
Øtincelles
et
des
particules
metalliques
volan
tes.
Pendant Ia
periode
de ref roidissement des
soudures,
elles
risquent
de
projeter
du
laitier.

Porter des
lunettes de
securite
avec
ecrans lateraux
ou
un
ecran facial.
iiai
LES
ACCUMULATIONS
DE
GAZ
ris
~4
quent
de
provoquer
des
blessures
ou
mØme
lamort.:
:
:.:
1,
L.J
.
Fermer
Ialimentation
du
gaz
protecteur
en
cas
de
non
utilisation.

Veillertoujours
a
bien
aerer
es
espaces
confines
ou se
servir
dun
respi
rafeur
dadduction
dair
homologue.
DESI
PI¨CES CHAUDES
peuieæt
pro
vquer
des
brOlures
graves.

Ne
pas
toucher
des
parties
chaudes
a
mains
nues

Prevoir
une
pOriode
de
refroidissement
avant
dutiliser
le
pistolet
ou
Ia torche.
LES
CHAMPS
MAGNETIQUES
peuvent
affecter
les stimulateurs
cardiaques.

Porteurs de
stimulateurcardiaque,
restez
a
distance.

Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord consulter leur
medecin
avant
de
sapprocher
des
operations
de
soudage
a
Iarc,
de
gougeage
ou
de
soudage
par
points.
LE BRUIT
peut
affecter IouIe.
Le bruit des processus
et
des
equmpements
peuf
affecter
louie.

Porter des
protections
approuves
pour
les
oreilles si
le niveau sondre
est
trop
eleve.
Si des BOUTE1LLES
sont
endomma
gSa,
elles
pourront
exploser.
Des bouteilles
de
gaz
profecteur
contiennent
du
gaz
sous
haute
pression.
Si
une
bouteille
est
endomma
gee,
elle
peutexploser.
Du
faitque
les bouteilles
de
gaz
font normalement
partie
du
procØdØ
de
soudage,
les
manipuler
avec
precaution.

ProtØger
les bouteilles de
gaz
comprimØ
dune chaleur
excessive,
des
chocs
mecaniques,
du
laitier,
des flammes
ouvertes,
des etin
celles
et
des
arcs.

Placer
les bouteilles
debout
en
les
fixant
dans
un
support
station
naire
ou
dans
un
porte-bouteilles
pour
les
empecher
de tomber
ou
de
se renverser.

Tenir
les
bouteilles
eloignees
des circuits de
soudage
ou
autres
cir
cuits
electriques.

Ne
jamais placer
une
torche de
soudage
sur une
bouteille
a
gaz.

Une electrode de
soudage
ne
doit
jamais
entrer
en
contact
avec
une
bouteille.

Ne
jamais
souder
une
bouteille
pressurisee

risque
dexplosion.

Ufiliser seulement des bouteilles de
gaz
pittecteur,
rØgulateurs,
tuyaux
et
raccords convenables
pour
cette
application
specifique;
les
mamntenir ainsi
que
les elements associes
en
bon
etat.

Ne
pas
tenir Ia
fŒte
en
face
de Ia
sortie
en
ouvranf
Ia
soupape
de Ia
bouteille.

Maintenir
le
chapeau
de
protection
sur
Ia
soupape,
sauf
en cas
dutilisation
ou
de branchement de Ia
bouteille.

Lire
et
suivre
es
instructions
concemant
les
bouteilles
de
gai
com
prime,
les
equipements
associes
et
les
publications
P-i
CGA
enu
mØrees
dans les
normes
de
securite.
DES PARTICULES
VOLANTES
_____
peuventblesser
les
yeux.
6
OM-2217

et
la
maintenance
Risque
DINCENDIE
OU
D!EXPLOSION.

Ne
pas
placer
lappareil
sur,
au-dessus
ou
a
proximite
de
surfaces
infilammables.
Ne
pas
installer
lappareil
a
proximitØ
de
produits
inflammables
Ne
pas
surcharger
installation
Ølectrique

sassurer
que
lalimen
tation
est correctement
dimensionnØ
et
protØgØ
avant
de
mettre
lappareil
en
service.
LA
CHUTE
DE
LAPPAREIL
peut
blesser.

Utiliserlanneau
de
levage
uniquementpoursou
lever
lappareil,
NON PAS
les
chariot,
les bouteil
es
de
gaz
ou
tout
autre accessoire.

Utiliser
un
engin
dune
capacitØ appropriee
pour
soulever
lappareil.

En
utilisant des
fourches
de
levage
pour
dØplacer
lunttØ,
sassurer
que
les fourches
sont
suffisamment
longues pourdØpasserdu
ctØ
oppose
de
Iappareil.
LEMPLOI
EXCESSIF
peut
SURCHAUFFER
LEQUIPEMENt

PrØvoir
une
pØnode
de
refroidissement,
respec
ter
le
cycle operatoire
nominal.

RØduirelecourantoulecycleopŁratoireavantde
recommancer
le
soudage.

Ne
pas
obstruer les
passages
dair du
poste.
LES
CHARGES
ELECTROSTATIQUES
peuvent
endommager
les
circuits
im
primes.

Etablir
Ia connexion
avec a
barrette de
terre
avant
de
manipuler
des
cartes
ou
des
piŁces.

Utiliser des
pochettes
et
des
boTtes
antistatiques
pour
stocker,
deplacer
ou
expØdier
des
cartes
de
circuits
impnmes.
I.
DES
ORGANES
MOBILES
~
Pr9V~qUe!
desbiessures.

Ne
pas
sapprocher
des organos
mobiles.

Ne
pas
sapprocher
des
points
de
coincement
tels
que
des rouleaux
de commande.
LES F1LS DE SOUDAGE
peuvent
pro
voquer
des blessures.

Ne
pas
appuyer
sur
Ia
gachette
avant
den
avoir
recu
instruction.

Ne
pas
dinger
le
pistolet
vers
soi,
dautres
per
sonnes
ou toute
piŁce mecanique
en
engageant
le
fil
de
soudage.
DES
ORGANES
MOBILES
peuvent
provoquer
des
blessures.

Rester
a
lŁcart
des
organes
mobiles
comme
le
ventilateur.

MaintenirfermŁs
et
fixement
en
place
les
portes,
panneaux,
recouvrements
et
dispositifs
do
protection.
LE
RAVONNEMENT
HAUTE
FRE
QUENCE
(H.F.)
risque
de
provoquer
des
interferences.

Le
rayonnement
haute
frequence
peut
provoquer
des
interferences
avec
les
equipements
de
ra
dionavigationet
de
communication,
los services
de
sØcuntØ
et
les
ordinateurs.

Demander
seulement
a
des personnes
qualifiees
familiansØes
avec
des
equipements
Łlectroniques
de
faire
fonctionner linstalla
tion.

Lutilisateur est
tenu
de
faire
corriger rapidemont
par
un
electncien
qualifie
les
interferences
resultant
do
linstallation.

Si
le
FCC
signale
des
interferences,
arrºterimmØdiatement
lappa
roil.

Effectuer
rŁgulierement
le
contrle
et
lentretien
de
installation.

Maintenir
soigneusement
fermes les
portes
et
les
panneaux
des
sources
do
haute
frOquence,
maintenir
les
Øclateurs a
une
distance
correcte
et
utiliser
uno
terre et et
un
blindage
pour
rØduire los
inter
fØrences
Øventuelles.
LE
SOUDAGE
A
LARC
risque
de
provoquer
des
interferences.

LŁnergie
ØlectromagnØtique
risque
do
provoquer
des interferences
pour
lŁquipement
electronique
sensible
tel
que
les
ordinateurs
et
lequipement
commandØ
par
ordinateur
tel
que
les
robots.

Veiller
ace
que
tout
lequipement
de
Ia
zone
de
soudage
soit
com
patible
electromagnetiquement.

Pour rØduire
Ia
possibilitŁ
dinterfØrence,
maintenir
los
cables
do
soudage
aussi
courts
quo
possible,
les
grouper,
et
es
poser
aussi
bas
quo
possible (ox.
par
terre).

Veiller
a souder a
une
distance
de
100
metres
do
tout
equipement
electronique
sensible.

Veiller a
ce
quo
ce
poste
de
soudage
soft
pose
et
mis
a
Ia
terre
contomiØment
a
ce
mode
demploi.

En
cas
dinterfØrences
aprŁs
avoir
pns
los
mesures
prØcOdentes,
il
incombe
a
lutilisateur
do
prendre
des
mesures
supplØmentaires
telles
que
le
deplacement
du
poste,
lutilisation
do
cables
blindØs,
lutilisation
de filtres de
ligne
ou
Ia
pose do
protecteurs
dans
Ia
zone
do
travail.
LES
CHAMPS
MAGNETIQUES
peuv~nt
affecter
les
stimulateurs
cardiaques.

Porteurs
do
stimulateur
cardiaque,
restez
a
dis
tance.

Las
porteurs
dun stimulateur
cardiaque
doivent
dabord consutter
leur mØdecin
avant
do
sappro
cher
des
operations
do
soudage
a
Iarc,
de
gou
geage
ou
de
soudage
par
points.
1.3
Dangers
supplØmentaires
en
relation
avec
linstallation,
le fonctionnement
OM-2217
7

1 4
Principales
normes
de
sØcurutØ
Safety
in
Welding
and
Cutting,
norme
ANSI Z49.1
de lAmencan
Wel
ding
Society,
550
N.W.
Lejeune
Rd,
Miami FL 33126
Safety
and Health
Sandards,
OSHA
29
CFR
1910,
du
Superintendent
of
Documents,
U.S.
Government
Pnnting
Office,
Washington,
D.C.
20402.
Recommended
Safe Practice
for
the
Preparation
for
Welding
and
Cut
ting
of Containers
That Have Held
Hazardous
Substances,
norrne
AWS
F4.1
,
de
lAmencan
Welding
Society,
550 N.W.
Lejeune
Rd,
Mia
mi
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
de Ia National
Fire Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
de
Ia
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Regles
de
sØcuritØ
en
soudage,
coupage
etprocØdØs
connexes,
nor-
me
CSA Wi
17.2,
de
Association canadienne de
normalisation,
vente
de
normes,
178
Rexdale
Boulevard,
Rexdale
(Ontario)
Canada
M9W
1R3.
Safe Practices
ForOccupationAnd
Educational
EyeAnd
Face Protec
tion,
norrne
ANSI
Z87.i,
de
American
National Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
and
Welding
Processes,
none
NFPA
51
B,
de Ia National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1.5
Information
sur
tes
champs
ØlectromagnØtiques
DonnØes
sur
le
soudage
electnque
et
sur es
effets,
pour
lorganisme,
des
champs
magnØtiques
basse
frØquence
Lextrait
suivant
est
tire
des conclusions
generales
du document
intitu
lØ
Biological
Effects
of
Power
Frequency
Electric &
Magnetic
Fields

Background
Paper,
OTABPE53
(Washington
DC:
U.S.
Govern
ment
Printing
Office,
mai
1989), publiØ
par
le
Office
of
Technology
Assessment
du
Congres
amØncain:
...
ii
existe maintenant dabon
dantes
donnØes
scientifiques compilOes
a
Ia suite
dexpØnences
sur
Ia
cellule
ou
dØtudes
sur
des animaux
et
des
humains,
qui
moritrent
clairement
que
les
champs
electromagnetiques
basse
frØquence
peu
vent
avoir des
effets
sur
lorganisme
et
mŒme
y
produire
des
transformations.
MŁme
sil
sagit
de
travaux
de
trØs
grande qualitØ,
les
rØsultats
sont
complexes.
Cette dØmarche
scientifique
ne nous
per-
met
pas
dØtablir
un
tableau densemble coherent. Pire
encore,
elle
ne
nous
perniet
pas de
tirer des conclusions finales
concemant
les
ns
ques
Øventuels,
ni
doffrir
des conseils
sur
les
mesures
a
prendre
pour
rØduire
sinon
Øliminer
les
nsques
Øventuels.
(Traduction libre)
Afin
de rØduire
les
champs
electromagnetiques
dans lenvironnement
de
travail,
respecter
les
consignes
suivantes
1
Garder
es
cables
ensembles
en
les
torsadant
ou en
les
attachant
avec
du
ruban
adhØsif.
2
Mettre
tous
les
cables
du
ctØ
oppose
de
Ioperateur.
3 Ne
pas
courber pas
et
ne
pas
entourer
pas
les cables
autour
de
vous.
4
Garder le
poste
de
soudage
et
es
cables
le
plus
loin
possible
de
vous.
5
Relier Ia
pince
de
masse
le
plus
prŁs possible
de
Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les
consignes
mentionnØes
precØdemment
font
partie
de celles desti
nØes
aux
personnes
ayant
recours
a
un
stimulateur
cardiaque.
Veuillez consultervotre mØdecin
pour
obtenir
plus
de details.
8
OM-2217

2.
Introduction
2.~1
Specifications
g~-~g
4
Minutes
Welding
6
Minutes
Resting
Overheating
~
~,
III, ~
-4
(~15~*
8A01-~
OR
Minutes
Reduce
Duty Cycle
Input
Power
Rated
Welding Output
Amperage
Range
Maximum
Open-Circuit
Voltage
DC
Amperes Input
at
Rated
Load
Output
60
Hz
230V
460V
KVA
KW
250A
'
3OVoItsAC,40%
26.3
17.9
14.2
10.5
Three Phase
Duty
Cycle
5-300
90
*.27
*15 .09 .04
200 A
'
28
Volts
DC,
40%
20.5
13.4 8.4 7.6
Duty
Cycle
*.27
*.15 .09 .04
250
A
'
30
Volts
AC,
40%
62.6
32.2 14.8 10.4
Single
Phase
Duty Cycle
5300
90
*33 *.18 *.10
*07
200
A
'
28
Volts
DC,
40%
Duty
Cycle
.33
25.8
*.18
11.9
.1
8.1
.07
While
idling
2,2
Duty Cycle
and
Overheating
~
Duty Cycle
is
percentage
of
10
minutes
that unit
can
weld
at
rated
load without
overheating.
sdutyl
5/95
/SA-185
794
If
unit
overheats,
output
stops,
a
Help
message
is
displayed
(see
Section
4.4),
and
cooling
fan
runs.
Wait fifteen minutes for
unit
to
cool.
Reduce
amperage
or
voltage,
or
duty cycle
before
welding.
.
Not Available
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
250 A
0
40%
Duty
Cycle
For
AC
200
A 0
40%
Duty
Cycle
For
DC
OM-221
7
9

(1)
F-
-J
0
>
U
U)
F-
-J
0
>
U
0
5A-185
793/SA-186
294
23
Volt-Ampere
Curves
Volt-ampere
curves
show
mini
mum
and
maximum
voltage
and
amperage
output
capabilities
of
100
unit.
Curves
of other
settings
fall
between
curves
shown.
80
60
40
20
0
100
80
60
40
20
0
0
50
100
150
200 250 300
350
AC
AMPERES
(250
HZ
@
BALANCED)
0
50
100 150 200
250
300
350
DC
AMPERES
10
OM-221
7

Ioc_2
3/96
-
ST-801
708
1
Lifting
Handles
Use handles
to
lift unit.
2
Hand
Cart
Use
cart
or
similar
device
to
move
unit.
3
Rating
Label
Use
rating
label
to
detem,ine
input
power
needs.
4
Line
Disconnect Device
Locate unit
near
correct
input
power
supply.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present

see
NEC Article 511
or
CEC
Section
20.
Dimensions
And
Weight
90 lb
(40.7
kg)
Movement
18
in
(460
mm)
24 in
(610 mm)
3
mm)
A
Do
not
move or
operate
unit
where
it could
tip.
Location
4
18 in
(460
mm)
OM-221
7
11

25
Weld
Output
Terminals and
Selecting
Cable
Sizes
S-0007-E
lOOft(30m)OrLess
150 ft
(45m)
200ft
(60m)
250
ft
(7Dm)
300
ft
(9Dm)
350 ft
(105m)
400ft
(12Dm)
100
4
4
4
3
2 1
1/0
1/0
150
3 3
2 1
1/0 2/0 3/0
3/0
200 3 2
1
1/0 2/0 3/0 4/0
4/0
250 2 1
1/0
2/0 3/0
4/0 2-2/0 2-2/0
300
1
1/0
2/0 3/0
4/0
2-2/0
2-3/0 2-3/0
Work
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0
2-3/0 2-4/0
WeId
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.
2.6
Remote 14
Receptacle
Information
*The
remaining
sockets
are
not
used.
ST-801
192
REMOTE
14
Socket
GND
G
K
Socket
Information
Circuit
common
for
24
volts
ac
circuits.
Chassis
common.
Weld
Output
Terminals
Total
Cable
(Copper)
Length
in Weld
Circuit
Not
Exceeding
Welding
Amperes
1060%
Duty
Cycle
60100%
10 100%
Duty
Cycle
Duty
Cycle
24
VOLTS AC
oPTPur
(OONTACTOR)
A
24
volts
ac.
Protected
by
circuit breaker
CB2.
B Contact closure
to
A
completes
24
volts
ac
contactor
control circuit.
REMOTE
OUTPUT
CONTROL
C
Output
to remote
control;
0
to
+10 volts
dc
output
to remote
control.
0 Remote control circuit
common.
E 0
to
+10
volts
dc
input
command
signal
from
remote
control.
M Remote
process.
AN
AMPERAGE
VOLTAGE
F
Current
feedback;
+1
volt dc
per
100
amperes.
H
Voltage
feedback;
+1
volt dc
per
10
output
receptacle
volts.
12
OM-221
7

1
ll5VlOAACReceptacle
Power is
shared
between
duplex
receptacle
and Remote
14
recep
tacle
(see
Section
2.6).
2
Power
On/Off Switch
Note
~
Actual
input
voltage
cannot
exceed
–
15%
of indicated
required input
voltage.
If
actual
input
voltage
is
outside of this
range,
no
output
is
available.
Input
Voltage
230 460
230
460
AC
Input
Amperes
At
Rated
Output
DC
26.5
17.9
62.6 32.2
20.5 13.4
44
25.8
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
50 25
100
50
Rating
In
Amperes
Reference:
1996 National Electrical Code
(NEC).
S-0092J
27
115
Volts AC
Duplex
Receptacle
(Optional)
and
Power
Switch
Location
2
1
ST-801
866
28
Electrical
Service
Guide
Three-Phase
Single-Phase
OM-221
7
13

29
Connecting
Input
Power
Check
input
voltage
available
at
site.
1
Input
And
Grounding
Conductors
2
Line
Disconnect
Device
See
Section
2.8.
For
single-phase
operation:
3
Black
And White
Input
Conductor
4
Red
Input
Conductor
5
Insulation
Sleeving
6
Electrical
Tape
Insulate and isolate
red conductor
as
shown.
A
Always
connect
green
wire
to
supply
grounding
termi
nal,
never
to
a
line terminal.
Connect
black,
white,
and
red
wires
(Li,
L2,
U)
to
line
terminals.
input_2
3/96
-
ST-801
709
Tools
Needed:
~
3/8in
cI::I:::::::J==iJ
3/8
in
3\,
1\,
A
Always
connect
grounding
conductor
first.
14
OM-2217

3.
Operation
Range
is
20
to
250
hertz.
For
most
applica
tions,
increasing
frequency
improves
arc
sta
bility.
2
Balance/DIG
Control
Control
functions
as a
balance
control
for
GTAW
(TIG)
process,
and
in
the DIG
mode for
SMAW
(STICK)
process,
depending
on
position
of
Process
control.
Balance Mode:
See Section
3.2.
DIG Mode:
When
set
lower;
short-circuit
amperage
at
low
arc
voltage
is the
same
as
normal
welding
am
perage.
When
set
higher,
short-circuit
amperage
is
in
creased
at
low
arc
voltage
to
help
with
arc
starting
and
making
overhead
or
vertical
welds,
as
well
as
to
reduce
sticking
while
welding.
3
Voltmeter
(see
Section
3.3)
Voltmeter
displays
voltage
(to
the
nearest
0.1
V)
at
the
weld
output
terrrrinals,
but
not
neces
sanly
the
welding
arc
due
to
cable
resistance,
poor
connections,
etc.
4
Ammeter
(see
Section
3.3)
Use
ammeter to
preset
amperage.
Meter
dis
plays
weld
amperage
output
of
unit
when
welding.
5
Amperage
Adjustment
Control
Turn
control clockwise
to
increase
amperage
from
5
to
300
amps.
6
Output
Control
Switch
See Section
3.4.
7
Amperage
Control Switch
For front
panel
control,
place
switch
in
Panel
position.
For
remote
control,
make connections
to
remote
14
receptacle,
and
place
switch
in
Remote
14
position.
8
Trigger
Hold
To
start
weld,
press
and
release
gun
trigger
within
three seconds
after
an arc
has been
struck. To end
weld,
press
and release
gun
trigger.
If
gun
trigger
is
not
released
within
3
seconds,
unit switches
to
standard
trigger
control
operation.
9 Process
Control
Use
control
to
select
either
of
the
GTAW
(TIG)
welding
process
and
polarity,
or
the
SMAW
(Stick)
welding
process.
Ref. ST-182
133
Selecting
any
GTAW
(hG) position
enables
the
gas
valve,
which
is disabled
when
SMAW
(Stick)
position
is
selected.
10
Sequence
Control
See
Section
3.5.
11
Start A
(Amperage)
Control
Use control
to
select
a
starting
amperage
that
is
difterent from
the weld
amperage.
12 Start
t
(Amperage lime)
Control
Use control
to
select
length
of time
in
seconds
that
amperage
remains
at start
amperage
be
fore
changing
to
weld
amperage.
For
example,
to
select
start
amperage
of
300
A
for
3 seconds and weld
amperage
of
200
A:
Set Start
A
amperage
control
to
300
A,
set
Start
t
time control
to
3
seconds,
and
set
front
panel
or
remote
amperage
control
to
200
A.
13
Crater Control
Control
sets
length
of time in seconds
to
taper
weld
output
from weld
amperage
setting
to
0
A
14
Postflow Control
Control
sets
length
of
time
in
seconds
gas
flows after the
welding
stops.
6
7
8
1
AC
Frequency
Control
1 2
3 4 5
AC
FREQ.
I
BALANCE/DIG
AMPS
ADJUST
ENCE
CONTRQ~
11
10
14
9
PROCESS
I
OUTPUT

AMPS
OM-2217
15

3.2 Ac/Balance Control
Balance
Control:
Control
changes
the
ac
output
square
wave.
Adjust setting
for
deeper
penetration
or
more
cleaning
action.
3.3
Meter
Function
Mode
Meter
Reading
At
Idle
Balance
Control
Waveform
Examples
Meter
Reading
While
Welding
.
.
.
50%
Electrode
Positive
~jLfiL
50% Electrode
U
Negative
On
I
80.0
85
I
Actual
Volts
(OCV)
Preset
Amps
24.5
I
85
Actual Volts Actual
Amps
LiftOn
7O~
85
Actual Volts
-
Preset
Amps
I
10.3
85
Actual Volts Actual
Amps
HF
Remote
I
85
Blank
Preset
Amps
1
0.3 85
Actual Volts Actual
Amps
Lift
Remote
I I
85
Blank
Preset
Amps
I
10.3
I I
85
I
Actual Volts Actual
Amps
Remote
I I
24.5 85
I
Blank Preset
Amps
Actual Volts
Actual
Amps
3.4
Output
Switch
Settings
Output
Switch
Setting
Process
Output
On/Off Control
On
GTAW
(TIG)/SMAW
(Stick)
Electrode
Hot
Uft ~,,
GTAW
(TIG)
With
Lift-Arc
Start
-
See
Section
3.6
Elect
de
Hot
ro
HF
Remote GTAW
(TIG)
With HF
Start

See
Section
3.6
At Remote
14
Lift
Remote
GTAW
(TIG)
At
Remote
14
Remote GTAW
(TIG)/SMAW
(Stick)
At Remote
14
16
OM-221
7