Miller Maxstar 300 User manual

CE
p
Visit
our
website
at
www.MillerWelils.com
OM-2210
18G8G50
February
1998
Processes
TIG
(GTAW) Welding
Stick
(SMAW) Welding
Description
Arc
Welding
Power
Source
Miner
The
Power
fBlue.
Maxstarfi
300
OWNERS
MANUAL

UflfflJLRfl~
L~t~W
Weiting
as
herd
as
you
do
-
every
power
anurce
from Riffler Is backed
by
the
meat
hassle-free
warranty
In
theboshiess.
From
Miller
to
You
.
Thank
you
and
congratulations
on
choosing
Miller.
Now
you
can
get
the
job
done
and
get
it done
right.
We
know
you
dont have time
to
do
it
any
other
way.
Thats
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
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
committed
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
 ~r
IREGISTERED
I
QUALITY SYSTEM
Miller Is the first
waldhig ellohIlloelfi
menofaclerer In the
U.S.A.
to
be
registered
lii
the
ISO OQU1
Ujeilly
System
Standard.
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.
Miller
offers
a
Technical
Manual
which
provides
more
detailed seavice
and
parts
information for
your
unit To obtain
a
Technical
Manual,
contact
your
local
distrThutoa Your
distributor
can
also
supply
you
with
Welding
Process
Manuals
such
as
SMAW,
GTAW,
GMAW,
and
GMAW-P
p
V//A
Miller
TheFbwerqfB&

call
1
-800-4-A-MIlJ.ER
for
yoor
local
Miller
disbihutur.
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.
Miller offers
a
Technical
Manual
which
provides
more
detailed service
and
parts
information
for
your
unit. To obtain
a
Technical
Manual,
contact
your
local
distributor. Your distributor
can
also
supply
you
with
Welding
Process
Manuals
such
as
SMAW, GTAW,
GMAW,
and
GMAW-P.
For
practical
information
on
welding,
process
applica
tions,
and Miller
products,
visit
our
website
at
wwwJ~IiIIerWfflds.cem
The
following
terms
are
used
interchangeably
throughout
this
manual:
TIG
=
GTAW
Stick
=
SMAW
TABLE
OF CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ BEFORE USING
1
1-1.
Symbol
Usage
1
1-2. Arc
Welding
Hazards
1
1-3.
Additional
Symbols
For
Installation,
Operation,
And
Maintenance
3
1-4.
Principal
Safety
Standards 3
1-5.
EMF
Information
4
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTILISATION
5
1-1.
Signification
des
symboles
5
1-2.
Dangers
relatifs
au
soudage
a
Iarc
5
1-3.
Dangers
supplØmentaires
en
relation
avec
installation,
le
fonctionnement
et
Ia
maintenance 7
1-4.
Principales
normes
de
sØcuritØ
8
1-5.
Information
sur
les
champs
Ølectromagnetiques
8
SECTION
2
-
DEFINITIONS
9
2-1.
Warning
Label Definitions 9
2-2.
Symbols
And Definitions
11
SECTION
3-OPERATION
12
3-1.
Specifications
12
3-2.
Duty
Cycle
And
Overheating
12
3-3.
Volt-Ampere
Curves
13
3-4.
Selecting
A
Location 13
3-5.
Weld
Output
Terminals And
Selecting
Cable Sizes
14
3-6. Remote
14
Receptacle
Information
14
3-7. Remote
4
Receptacle
Information
15
3-8.
115
Volts AC
Duplex Receptacle,
Circuit
breaker
(Optional),
And Power
Switch
15
3-9. Electrical
Service Guide
15
3-10.
Connecting
Input
Power 16
SECTION
4
-
OPERATION
18
4-1.
Controls
(See
Section
4-2)
18
4-2.
Description
Of Controls
(See
Section
4-1)
19
4-3.
Lift-ArcE
And
HF
TIG
Start Procedures 20
SECTION
5
-
MAINTENANCE AND TROUBLESHOOTING 20
5-1.
Routine Maintenance
20
5-2.
Blowing
Out
Inside
Of
Unit
21
5-3.
Voltmeter/Ammeter
Help
Displays
22
5-4.
Troubleshooting
23
SECTION
6
-
ELECTRICAL
DIAGRArvt
24
SECTION
6
-
HIGH
FREQUENCY
26
6-1.
Welding
Processes
Requiring High Frequency
26
6-2. Incorrect
Installation 26
6-3.
Correct
Installation
27
6.
Parts
List
28
WARRANTY
OM-221
8D

Declaration
of
Conformity
For
European
Community
(CE)
Products

N
OTE
~
This
information
is
provided
for
units
with
CE
certification
(see
rating
label
on
unit.)
Manufacturers
Name:
Miller
Electric
Mfg.
Co.
Manufacturers
Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares
that the
product:
IVI
axsta
r
300
fi
conforms
to
the
following
Directives
and
Standards:
Directives
Low
Voltage
Directive:
73/23/EEC
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Electromagnetic
Capability
Directives:
89/336,
92/31/EEC
Standards
Safety
Requirements
forArc
Welding
Equipment
part
1:
EN
60974-1: 1990
Arc
Welding
Equipment
Part
1:
Welding
Power
Sources:
IEC
974-1
(December
1996
-
Draft
revision)
Degrees
of
Protection
provided
by
Enclosures
(IP
code):
IEC
529:
1989
Insulation
coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles,
requirements
and
tests:
IEC
664-1:1992
Electromagnetic
compatibility
(EMC)
Product standard for
arc
welding
equipment:
EN50199:
August
1995
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
SPA.
Via
Privata
Iseo
20098
San Giuliano
Milanese,
Italy
39(02)98290-1
39(02)9828
1
-552
European
Contact:
Telephone:
Fax:
.
dec
coni
10/95

SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_5/97
1-1.
Symbol
Usage
a
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.
ELECTRIC SHOCK
can
kill.
Touching
live electrical
parts
can
cause
fatal
shocks
or severe
burns. The electrode and work
circuit
is
electrically
live
whenever the
output
is
on.
The
input
power
circuit and machine internal
circuits
are
also live
when
power
is
on.
In semiautomatic
or
automatic wire
welding,
the
wire,
wire
reel,
drive roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly grounded equipment
is
a
hazard.

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
OSHA
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
properly
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 off
all
equipment
when
not
in
use.

Do
not
use
worn, damaged,
undersized,
or
poorly spliced
cables.

Do
not
drape
cables
over
your
body.
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.

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
different machine.

Use
only
well-maintained
equipment.
Repair
or
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.

Do
not connect
more
than
one
electrode
or
work cable
to
any
single
weld
output
terminal.
SIGNIFICANT DC VOLTAGE
exists
after removal
of
input
power
on
inverters.

Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions in Maintenance
Section
before
touching
any
parts.
FUMES
AND
GASES
can
be
hazardous.
Welding produces
fumes
and
gases.
Breathing
=9~
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
white
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
degreasirig,
cleaning,
or
spraying
operations.
The heat and
rays
of
the
arc can
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
off toxic fumes if welded.
OM-2218
Page
1

ARC
RAYS
can
burn
eyes
and
skin
Arc
rays
from the
welding
process
produce
intense
visible and invisible
(ultraviolet
and
infrared)
rays
that
can
burn
eyes
and skin.
Sparks fly
off from
the
weld.

Wear
a
welding
helmet fitted with
a
proper
shade of filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.i
and Z87.i
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;
warn
others
not to
watch
the
arc.

Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
WELDING
an
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can cause
them
to
blow
up.
Sparks
can
fly
off from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot.equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
orfire.
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 METAL
can
injure
eyes.

Welding,
chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal. As
welds
cool,
they
can
throw
off
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
1J
approved
air-supplied
respirator.
HOT
PARTS
can
cause severe
burns

Do
not
touch
hot
parts
bare handed.

Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affect
pacemakers.

Pacemaker
wearers
keep
away.

Wearers should
consult their doctor
before
going
near
arc
welding, gouging,
or
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.
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
over
valve
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.
CYLINDERS
can
explode
if
damaged.




OM-221
8
Page
2

FIRE OR
EXPLOSION hazard.

Do
not
install
or
place
unit
on, over,
or
near
combustible
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
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,
Batterymarch
Park,
Quincy,
MA
02269.

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,
Rexd
ale,
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
MOVING PARTS
can
cause
injury.
OM-22i
8
Page
3

1-5
EMF
Information
Considerations
About
Welding
And The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
Welding
current,
as
it flows
through welding
cables,
will
cause
electro
magnetic
fields. There
has
been
and
still
is
some
cc~ncern
about
such
fields.
However,
after
examining
more
than
500
studies
spanning
17
years
of
research,
a
special
blue ribbon committee of the
National
Research Council
concluded that: The
body
of
evidence,
in
the
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
frequency
electric and
magnetic
fields is
a
human-health hazard.
However,
studies
are
still
going
forth and evidence
continues
to
be
examined.
Until
the
final conclusions of
the research
are
reached,
you
may
wish
to
minimize
your
exposure
to
electromagnetic
fields
when
welding
or
cutting.
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
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
possible.
About
Pacemakers:
Pacemaker
wearers
consult
your
doctor first. If
cleared
by
your
doctor,
then
following
the
above
procedures
is
recommended.
OM-221
8
Page
4

4A
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.
~
Signifle
NOTA
nest
pas
relatif
a
Ia
sØcuritØ.
1-2.
Dangers
relatifs
au
soudage
a
Iarc
A
Les
symboles
presentØs
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
prØsentØes ci-aprŁs
ne
font
que
rØsumer
lintormation
contenue dans les
normes
de
sØcuritØ
ØnumØrØes
a
Ia section 1-4. Veuillez lire
et
respecter
toutes
ces
normes
de
sØcuritØ.
A
Linstallation,
lutilisation,
lentretien
et
les
reparations
ne
doi
vent
Œtre
contiØs
quØ
des
personnes
qualifiees.
A
Au
cours
de
lutilisation,
tenir
toute
personne
a lØcart
et
plus
par
ticuliŁrement
les enfants.
UN CHOC
ELECTRIQUE
peut
tuer.
Un
simple
contact
avec
des
piŁces
Ølectriques
peut
provoquer
une
electrocution
ou
des
blessures
graves.
LØlectrode
et
le circuit de
soudage
sont
sous
tension
des que
Iappareil
est
sur
ON.
Le circuit
dentrØe
et
es
circuits internes
de
Iappareil
sont
Øgalement
sous
tension
a
ce
moment-l.
En
soudage semi-automatique
ou
automatique,
le
fil,
le
dŁvidoir,
le
logement
des
galets
dentrainement
et
les
piŁces
mŁtalliques
en
contact
avec
le fil de
soudage
sont
sous
tension. Des
matŁriels
mal
installŁs
ou
mal mis
a
Ia
terre
prŁsentent
un
danger.

Ne
jamais
toucher
les
piŁces Łlectriques
sous
tension.

Porter des
gants
et
des
vŒtements
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
empŒcher
le
contact
phy
sique
Łventuel
avec
Ia
piŁce
ou
Ia
terre.

Ne
pas
se
servir
de
source
electrique
courant
electrique
dans les
zones
humides,
dans les endroits confines
ou
l
o
on
risque
de tomber.

Se
servir dune
source
electrique
couranl
Ølectrique
UNIQUEMENT
si le
procŁdØ
de
soudage
le demande.

Si
lutilisation dune
source
electrique
courant
Ølectrique
savŁre
nØces
saire,
se
servir
de Ia
fonction
de
tØlØcommande
Si
lappareil
en
est
ØquipØ.

Couper
lalimentation
ou
arrØter
le
moteuravant
de
procŁder
a
instal
lation,
a
Ia
reparation
ou
a
lentretien
de
Iappareil.
DŁverrouiller
lalimentation
selon Ia
norme
OSHA
29
CFR
1910.147
(voir
normes
de
sŁcuritŁ).

Installer
et
mettre
ala
terre
correctement cet
appareil
conformŁment a
son
manuel
dutilisation
et
aux
codes
nationaux,
provinciaux
et
municipaux.

Toujours
vŁrffier
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 sectionneur
ou
que
Ia
fiche
du cordon
est
raccordŁe
a
une
prise
correctement
mise
a
Ia
terre.

En effectuant
les
raccordements
dentrŁe
fixer
dabord le conducteur
de
mise
a
Ia
terre
appropriŁ
et
contre-vŁrifier
les
connexions.

Verifier
frequemment
le cordon dalimentation
pour
voir
sil
nest
pas
endommage
ou
dØnudŁ

remplacer
le
cordon
immØdiatement
sil
est
endommagŁ

un
cable
dŁnudŁ
peut
provoquer
une
electrocution.

Mettre
lappareil
hors
tension
quand
on ne
lutilise
pas.

Ne
pas
utiliser des
cables
uses,
endommagŁs,
de
grosseur
insuffi
sante
ou
mal
ŁpissŁs.

Ne
pas
enrouler les
cables
aLitour
du
corps.

Si
Ia
piŁce
soudØe
dolt
Œtre
mise
a
Ia
terre,
le
faire
directement
avec un
cable
distinct

ne
pas
utiliser le
connecteur
de
piŁce
ou
le
cable
de
retour.
Ce
groupe
de
symboles
signifie
Mise
en
garde
!
Soyez vigilant
II
y
a
des
risques
de
danger
relies
aux
CHOCS
ELECTRIQUES,
aux
PIECES
EN
MOUVEMENJT
et
aux
PIECES
CHAUDES.
Reportez-vous
aux
symboles
et
aux
directives ci-dessous
afin
de
connaltre
les
mesures
a
prendre
pour
Łviter
tout
danger.

Ne
pas
toucher
lŁlectrode
quand
on
est
en
contact
avec
Ia
piŁce,
Ia
terre
ou une
electrode
provenant
dune
autre
machine.

Nutiliser
quun
materiel
en
bon
Łtat.
RØparer
ou
remplacer
sur-le
champ
les
piŁces
endommagŁes.
Entretenir
lappareil
conformŁment
ace
manuel.

Porter
un
harnais de
sŁcuritŁ
quand
on
travaille
en
hauteur.

Maintenir solidement
en
place
tous
les
panneaux
et
capots.

Fixer le
cable
de
retour
de
facon
a
obtenir
un
bon
contact
mŁtal-mŁtal
avec
Ia
piŁce
a
souder
ou
a
table de
travail,
le
plus
prŁs
possible
de Ia
soudure.

Isoler Ia
pince
de
masse
quand
pas
mis
a
Ia piŁce
pour
Łviter le
contact
avec
tout
objet
mŁtallique.
Ily
a
DU
COURANT CONTINU IMPORTANT
dans les
convertisseurs
aprŁs
Ia
suppression
de Ialimenta
tion
Ølectrique.

ArrŒter
les
convertisseurs,
dŁbrancher
le
courant
Łlectrique,
et
dŁ
charger
les
condensateurs dalimentation selon
es
instructions
indiquŁes
dans Ia
partie
entretien
avant
de toucher les
piŁces.
I
~
LESFUMEES
ET LES GAZ
peuvent
~
Œtre
dangereux.
L.._
~
Le
soudage
gŁnŁre
des
fumŁes
et
des
gaz.
Leur
inhalation
peut
Œtre
dangereux
pour
votre
sante.
_____________

Eloigner
votre
tŒte
des
tumŁes.
Ne
pas
respirer
es
fumØes.

A
IintŁrieur,
ventiler
Ia
zone
et/ou
utiliser
un
Łchappement
au
ni
veau
de Iarc
pour
evacuation
des
fumŁes
et
des
gaz
de
soudage.

Si
Ia ventilation
est
insuffisante,
utiliser
un
respirateur
a
alimenta
tion
dair
homologue.

Ure les
specifications
de
sŁcuritŁ
des
matØriaux
(MSDS5)
et
les ins
tructions
du
fabricant
concernant
tes
mŁtaux,
es
consommables,
les
revØtements,
les
nettoyants
et
Ies
dØgraisseurs.

Travailler
dans
un
espace
fermŁ
seulement
siI
est
bien
ventilŁ
ou
en
portant
un
respirateur
a
alimentation
dair. Demander
toujours
a
un
surveillant
dment formŁ
de
se
tenir
a
proximitØ.
Des
fumŁes
et
des
gaz
de
soudage
peuvent
dØplacer
air
et
abaisser le niveau
doxygŁne
provoquant
des blessures
ou
des accidents
mortels.
Sassurer
que
lair de
respiration
ne
prŁsente
aucun
danger.

Ne
pas
souder dans
des
endroits
situŁs a
proximitŁ dopØrations
de
degraissage,
de
nettoyage
ou
de
pulvŁrisation.
La chaleur
et
les
rayons
de Iarc
peuvent reagir
en
presence
de
vapeurs
et
former
des
gaz
hautement
toxiques
et
irritants.

Ne
pas
souder
des
mŁtaux
munis dun
revŒtement,
tels
que
Iacier
galvanisØ, plaque
en
p10mb
ou
au
cadmium
a
moms
que
le
revŒte
ment
nait
ØtØ enlevŁ
dans Ia
zone
de
soudure,
que
Iendroit soft
bien
ventilØ,
et
si
nŒcessaire,
en
portant
un
respirateur
a
alimenta
tion dair. Les
revŒtements
et
tous
les
mØtaux
renfermant
ces
ŁlØ
ments
peuvent degager
des
fumØes
toxiques
en cas
de
soudage.
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
O
UTILISATION
1-1
Signification
des
symboles
som
_nd_tre
5/97
OM-2218
page
5

::LES RAVONS
bE
LARCpeuventpro
voquerdesbrulth.es
dans
IØsyeux
et
sur
Ia
peau
Le
rayonnement
de
arc
du
procØdØ
de
soudage
gØnŁre
des
rayons
visibles
et
invisibles
intenses
(ultraviolets
et
infrarouges)
susceptibles
de
provoquer
des
brOlures
dans
les
yeux
et
sur
Ia
peau.
Des
Øtincelles
sont
projetØes
pendant
le
soudage.

Porter
un
casque
de
soudage
muni dun
Øcran
de
filtre
appropriØ
pour
protØger
votre
visage
et
vos
yeux
pendant
le
soudage
ou
pour regar
der
(voir
ANSI Z49.1
et
Z87.1
ØnumØrØ
dans
es normes
de
sØcuritØ).

Porter des
protections
approuvØs
pour
es
oreitles site niveau sondre
est
trop
ØlevØ.

Utiliser des
Øcrans
ou
des
barriŁres
pour
protØger
des
tiers
de
lØclair
et
de
lØblouissement;
demander
aux
autres
personnes
de
ne
pas
re
garder
larc.

Porter
des
vŒtements
de
protection
constituØ
dans
une
matiŁre
dura
ble,
resistant
au
feu
(cuir
ou
lame)
et
une
protection
des
pieds.
~
LE
SOLJDAGE
peut
provoquer
I k
(~-:.i
incendie
ou
une
explosion.
~
Le
soudage
eftectuØ
sur
des
conteneurs
fermØs
tets
que
des
reservoirs,
tambours
ou
des conduites
peut
provo9uer
leur
Øclatement.
Des
Øtincelles
peuvent
Œtre
projetees
de arc de
soydure.
La
projection
dØtincel
les,
des
piŁces
chaudes
et
des
Øquipements
chauds
peut
provoquer
des
incendies
et
des
brlures.
Le
contact
accidentel de
lØlectrode
avec
des
objets
mØtalliques
peut
provoquer
des
Øtincelles,
une
explosion,
un
surchauffement
ou un
incendie. Avant de
commencer
le
soudage,
verifier
et
sassurer
que
lendroit
ne
prØsente
pas
de
danger.

Se
protØger
et dautres
personnes
de Ia
projection
dØtincelles
et
de
metal
chaud.

Ne
pas
souder dans
un
endroit
l
ou
des
Øtincelles
peuvent
tomber
sur
des substances
inflammables.

DØplacer
toutes
les substances
inflammables
a
une
distance de
10,7
m
de
larc
de
soudage.
En
cas
dimpossibilitØ
les
recouvrir
soigneuse
ment
avec
des
protections
homologuØs.

Des
Øtincelles
et
des
matØriaux
chauds
du
soudage
peuvent
facile
ment
passer
dans dautres
zones en
traversant
de
petites
fissures
et
des
ouvertures.

Surveiller
tout dØclenchement
dincendie ettenir
un
extincteur
a
proxi
mite.

Le
soudage
effectuØ
sur un
plafond,
plancher, paroi
ou
separation
peut
dŁclencher
un
incendie
de lautre
ctØ.

Ne
pas
effectuer
le
soudage
sur
des
conteneurs
fermŁs
tels
que
des
reservoirs,
tambours,
ou
conduites,
a
moms
quils
naient
ØtØ
prØpa
rØs
correctement
conformØment
a
AWS F4.1
(voir
les
normes
de
sØcuritŁ).

Brancher
le
cable
sur
Ia
piŁce
le
plus
prŁs
possible
de Ia
zone
de
sou
dage
pour
Øviter
le
transport
du
courant
sur une
longue
distance
par
des chemins inconnus
Øventuels
en
provoquant
des
risques
dØlec
trocution
et
dincendie.

Ne
pas
utiliser
le
poste
de
soudage
pour
degeler
des conduites
ge
lees.

En
cas
de
non
utilisation,
enlever
a
baguette
dØlectrode
du
porte
electrode
ou
couper
le fil
a
Ia
pointe
de
contact.

Porter
des
vŒtements
de
protection
dØpourvus
dhuile
tels
que
des
gants
en
cuir,
une
chemise
en
matØriau
lourd,
des
pantalons
sans
re
vers,
des
chaussures
hautes
et
un couvre
chef.

Avant
de
souder,
retirer
toute
substance
combustible de
vos
poches
telles
quun
allumeur
au
butane
ou
des
allumettes.
DES PARTICULES VOLANTES
peuvent
blesser les
yeux.

Le
soudage,
lŁcaillement,
le
passage
de
Ia
piŁce
a
Ia brosse
en
fil
de
fer,
et
le
meulage
gŁnererlt
des
Øtincelles
et
des
particules
mØtalliques
volan
tes.
Pendant Ia
pØriode
de refroidissement des
soudures,
elles
risquent
de
projeter
du
laitier.

Porter
des lunettes de
sØcuritØ
avec
Øcrans
latØraux
ou Un
Øcran
facial.
LES. AC~iJMULATlONS
DE.
GAl ris
~
quent deprovquer
des
blessures
mŒme
l
mart.
:
:
.
L.~J

Fermer latimentation
du
gaz
protecteur
en cas
non
utilisation.

Veiller
toujours
a
bien
aØrer
les
espaces
confines
ou se
servir dun
respi
rateur
dadduction
dair
homologue.
DES
PI¨CES
CHAUbES
peuvent
pro
voquer
des:brlures.
graves.

Ne
pas
toucher
des
parties
chaudes
a
mains
nues

PrŁvoir
une
pØriode
de refroidissement
avant
dutiliser
le
pistolet
ou
Ia
torche.

LES
CHAMPS
MAGNETIQUES
peuvent
aftecter
les stimulateurs
cardiaques.

Porteurs
de
stimutateur
cardiaque,
restez
a
distance.

Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord consutter
leur
mØdecin
avant
de
sapprocher
des
operations
de
soudage
a
larc,
de
gougeage
ou
de
soudage
par
points.
LE
BRUIT
peut
affecter
louIe.
Le
bruit des
processus
et
des
equipements
peut
affecter
louIe.

Porter
des
protections
approuvØs
pour
les oreilles Si
le niveau
sondre
est
trop
ØlevØ.
Si
des BOUTEILLES
sont
endomma
gØes,
eVes
pourront
exploser.
Des
bouteilles
de
gaz
protecteur
contiennent du
gaz
sous
haute
pression.
Si
une
bouteille
est
endomma
gee,
elle
peut
exploser.
Du
faitque
les
bouteilles de
gaz
font
normalement
partie
du
procØdØ
de
soudage,
les
manipuler
avec
precaution.

ProtØger
es
bouteilles de
gaz
comprimØ
dune chaleur
excessive,
des
chocs
mecaniques,
du
laitier,
des
flammes
ouvertes,
des
Øtin
celles
et
des
arcs.

Placer
les bouteilles
debout
en
les
fixant
dans
un
support
station
naire
ou
dans
un
porte-bouteilles
pour
es
empŒcher
de tomber
ou
de
se
renverser.

Tenir
les bouteilles
Øloignees
des circuits de
soudage
ou
autres
cir
cuits
Ølectriques.

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
pressurisØe

risque
dexplosion.

Utiliser
seulement
des bouteilles de
gaz
protecteur, rØgulateurs,
tuyaux
et
raccords
convenables
pour
cette
application
specifique;
les maintenir ainsi
que
les
ØlØments associØs
en
bon
Øtat.

Ne
pas
tenir Ia
tŒte
en
face
de Ia
sortie
en
ouvrant
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 les
instructions
concernant
les bouteilles de
gaz
corn
prime,
les
Œquipements
associØs
et
es
publications
P-i CGA
Œnu
mŒrØes
dans les
normes
de
sŒcuritØ.
OM-2218
Page
6

Risque
DINCENDIE
OU
DEXPLOSION.
 Ne
pas
placer
lappareil
sur,
au-dessus
ou
a
proximitØ
de
surfaces ~nfllammables.

Ne
pas
installer
lappareil
a
proximitØ
de
produits
inflammables

Ne
pas
surcharger
Iinstallation
electrique

sassurer
que
lalimen
tation
est
correctement
dimensionnØ
et
protØgØ
avant
de
mettre
lappareil
en
service.
LA
CHUTE
DE LAPPAREIL
peut
blesser.

Utiliser lanneau de
levage uniquement
pour
sou
lever
lappareil,
NON
PAS
les
chariot,
les
bouteil
les de
gaz
ou
tout
autre
accessoire.
 Utiliser
un
engin
dune
capacitØ
appropriØe
pour
soulever
lappareil.

En utilisant
des
fourches
de
levage
pour
dØplacer
lunitØ,
sassurer
que
es
fourches
sont
suffisamment
longues
pour
dØpasser
du
ctØ
oppose
de
lappareil.
L~EMPLOI
EXCESSIF
peut
SURCHAUFFER
LEQUIPEMENT.
 PrØvoir
une
pØriode
de
refroidissement,
respec
ter
le
cycle
opØratoire
nominal.
 RØduire
le
courant
ou
le
cycle
opØratoire
avant
de
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
Ia barrette
de
terre
avant
de
manipuler
des
cartes
ou
des
piŁces.
 Utiliser des
pochettes
et
des
boites
antistatiques
pour
stocker, dØplacer
ou
expØdier
des
cartes
de
circuits
imprimes.
DES
ORGANES
MOBILES
petivent.
provoquer
des blesSures..

Ne
pas
sapprocher
des
organes
mobiles.

Ne
pas
sapprocher
des
points
de
coincement
tels
que
des rouleaux de commande.
LES
FILS
DE
SOUDAGE
peuvent
pro
voquer
des blessures.

Ne
pas
appuyer
sur
Ia
gachette
avant
den
avoir
recu
linstruction.

Ne
pas
diriger
le
pistolet
vers
soi,
dautres
per
sonnes
ou
toute
piŁce mØcanique
en
engageant
le
fil
de
soudage.
DES
RGANES
MOBILES
peuvent
provoquer
des blessures.

Rester
a lØcart
des
organes
mobiles
comme
le
ventilateur.

Maintenir
fermØs
et
fixement
en
place
les
portes,
panneaux,
recouvrements
et
dispositifs
de
protection.
LE
IRAYONNEMENT
HAUTE
FRE
QUENCE
(H.F.) risque
de
provoquer
des
interferences.

Le
rayonnement
haute
frequence
peut
provoquer
des
intertØrences
avec
les
Øquipements
de
ra
dionavigation
et
de
communication,
es
services
de
sØcuritØ
et
les ordinateurs.

Demander seulement
a
des
personnes
qualifiØes
familiarisØes
avec
des
Øquipements
Ølectroniques
de
faire fonctionner
linstalla
tion.

Lutilisateur est
tenu
de
faire
corriger
rapidement
par
un
Ølectricien
qualifiØ
les
interferences
resultant
de
linstallation.

Si
le
FCC
signale
des
interferences,
arrŒter immØdiatement
lappa
reil.

Effectuer
reguliŁrement
le
contrle
et
lentretien de
linstallation.

Maintenir
soigneusement
fermØs
es
portes
et
les
panneaux
des
sources
de haute
frØquence,
maintenir
es
Øclateurs a
une
distance
correcte et
utiliser
une
terre
et et
un
blindage
pour
rØduire
les inter
fØrences Øventuelles.
LE
SOUDAGE
A
L?ARC
risque
de
provoquer
des
interferences.

LØnergie
ØlectromagnØtique
risque
de
provoquer
des
interferences
pour
Iequipement
Ølectronique
sensible
tel
que
les
ordinateurs
et
lequipement
commandØ
par
ordinateur
tel
que
les robots.

Veiller
ace
que
tout
lØquipement
de
Ia
zone
de
soudage
soit
com
patible
electromagnetiquement.

Pour
rØduire
Ia
possibilitØ
dinterfØrence,
maintenir
les
cables
de
soudage
aussi
courts
que
possible,
les
grouper,
et
les
poser
aussi
bas
que
possible
(ex.
par
terre).

Veiller
a
souder
a
une
distance de 100
metres
de tout
Øquipement
Ølectronique
sensible.

Veiller
a
ce
que
ce
poste
de
soudage
soit
pose
et
mis
a
Ia
terre
conformØment
a
ce
mode
demploi.

En
cas
dinterfØrences
aprŁs
avoir
pris
les
mesures
precØdentes,
il
incombe
a
lutilisateur
de
prendre
des
mesures
supplØmentaires
telles
que
le
dØplacement
du
poste,
lutilisation de
cables
blindØs,
lutilisation
de
filtres
de
ligne
ou
Ia
pose
de
protecteurs
dans Ia
zone
de travail.
LES
CHAMPS
MAGNETJQUES
peuvent
affecter
les stimulateurs
cardiaques.

Porteurs
de stimulateur
cardiaque,
restez
a
dis
tance.

Les
porteurs
dun stimulateur
cardiaque
doivent
dabord consutter leur
mØdecin
avant
de
sappro
cher
des
operations
de
soudage
a
Iarc,
de
gou
geage
ou
de
soudage
par
points.
1-3.
DangerssupplØmentaires
en
relation
avec
linstallation,
le
fonctinnement
et
Ia
maintenance
OM-2218
page
7

Safety in
Welding
and
Cutting,
norme
ANSI
Z49.1,
delAmerican
Wel
ding
Society,
550
N.W.
Lejeune
Rd,
Miami
FL
33126
Safetyand
Health
Sandards,
OSHA
29
CFR
1910,
du
Superintendent
of
Documents,
U.S. Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practice for the
Preparation
for
Welding
and
Cut
ting
of
Containers
That
Have Held
Hazardous
Substances,
norme
AWS
F4.1,
de American
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.
RØgles
de
sØcuritØ
en
soudage,
coupage
et
procØdØs
connexes,
nor-
me
CSA
Wi
17.2,
de
lAssociation
canadienne de
normalisation,
vente
de
normes,
178
Rexdale
Boulevard,
Rexdale
(Ontario)
Canada M9W
1R3.
Safe
Practices
For
Occupation
And Educational
Eye
And Face Protec
tion,
norme
ANSI
Z87.1,
de lAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
and
Welding
Processes,
norme
NFPA
51
B,
de Ia National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-5.
Information
sur
les
champs
ØlectromagnØtiques
DonnØes
sur
le
soudage
Ølectrique
et
sur
les
effets,
pour
lorganisme,
des
champs
magnØtiques
basse
frØquence
Le
courant
de
soudage, pendant
son
passage
dans les
cables
de
sou
dage,
causera
des
champs
ØlectromagnØtiques.
II
y
a
eu
et
il
y
a
encore
un
certain
souci
a
propos
de tels
champs.
Cependant,
aprŁs
avoir
examine
plus
de
500
etudes
qui
ont
ØtØ
faites
pendant
une
pØ
node de
recherche
de
17
ans,
un
comitØ
special
ruban
bleu du
National
Research
Council
a
conclu: L.accumulation
de
preuves,
sui
vant
le
jugement
du
comitØ,
na
pas
dØmontrØ
que
exposition
aux
champs
magnØtiques
et
champs
Ølectriques
a
haute
frØquence
reprØ
sente
un
risque
a
Ia
sante
humaine.
Toutefois,
des
etudes
sont
toujours
en
cours
et
es
preuves
continuent
a
Œtre examinØes.
En
at
tendant
que
les
conclusions finales
de Ia recherche soient
Øtablies,
il
vous
serait
souhaitable de
rØduire
votre
exposition
aux
champs
Ølec
tromagnØtiques
pendant
le
soudage
ou
le
coupage.
Afin
de
rØduire
es
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
lopØrateur.
3 Ne
pas
courber
pas
et
ne
pas
entourer
pas
les
cables
autour
de
votre
corps.
4
Garder
le
poste
de
soudage
et
les
cables
le
plus
loin
possible
de
vous.
5
Relier
a
pince
de
masse
le
plus
prŁs
possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les
personnes
qui
portent
un
stimulateur
cardiaque
doivent
avant tout
consulter leur
docteur. Si
vous
Œtes
dØclarØ
apte
par
votre
docteur,
il
est
alors
recommandØ
de
respecter
les
consignes
cidessus.
1-4
Principales
normes
de
securite
.
OM-2218
Page
8

SECTION
2- DEFINITIONS
2-1.
Warning
Label Definitions
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
1
Electric
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Wear
dry insulating gloves.
Do
not touch
electrode
with
bare hand.
Do
not
wear
wet
or
damaged gloves.
1 .2
Protect
yourself
from electric
shock
by insulating
yourself
from work and
ground.
1.3
Disconnect
input plug
or
power
before
working
on
machine.
2
Breathing
welding
fumes
can
be hazardous
to
your
health.
2.1
Keep
your
head
out
of
the
fumes.
2.2
Use forced ventilation
or
local
exhaust
to
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
a
watchperson
ready
to
use
it.
3.3
Do
not
weld
on
drums
or
any
closed containers.
4
Arc
rays
can
burn
eyes
and
injure
skin.
4.1
Wear hat and
safety
glasses.
Use
ear
protection
and button
shirt collar.
Use
welding
helmet with
correct
shade
of
filter. Wear
complete body
protection.
5
Become trained
and read the
instructions
before
working
on
the machine
or
welding.
6
Do
not
remove or
paint
over
(cover)
the label.
OM-2218
Page
9

d??
L
=
<600
~
k
9:~
~1793O9~A
.
Warning!
Watch Out!
There
are
possible
hazards
as
shown
by
the
symbols.
1
Electric
shock
from
wiring
can
kill.
2
Disconnect
input
plug
or
power
before
working
on
machine.
3
Hazardous
voltage
remains
on
input
capacitors
after
power
is
turned off. Do
not
touch
fully
charged
capacitors.
4
Always
wait
60
seconds
after
power
is
turned
off
before
working
on
unit,
OR
5
Check
input
capacitor
voltage,
and
be
sure
it is
near
0
before
touching
any
parts.
6
When
power
is
applied
failed
parts
can
explode
or cause
other
parts
to
explode.
7
Flying
pieces
of
parts
can
cause
injury.
Always
wear a
face
shield when
servicing
unit.
8
Always
wear
long
sleeves
and
button
your
collar when
servicing
unit.
9
After
taking
proper
precautions
as
shown,
connect
power
to
unit.
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Falling equipment
can
cause
injury
and
damage
to
unit.
3
Always
lift
and
support
unit
using
both
handles.
Keep
angle
of
lifting
device less
than 60
degrees.
4
Use
a
proper
cart
to
move
unit.
_________
5
Do
not
use one
handle
to
lift
or
support
unit.
\
\
4
5
1/96
OM-2218
Page
10

2-2.
Symbols
And
Definitions
A
Amperes
PanelLocal
Gas
Tungsten
Arc
Welding
(GTAW)
I
~
Shielded
Metal Arc
Welding
(SMAW)
–~L
V
Volts
Input
3
Phase Static
Frequency
~I~Z1-GD-I~!I~
Converter-Transformer-Rectifier
Output
0
0
~
Circuit
Breaker Remote
Touch Start
-
(GTAW)
(Ground)
~
Protective Earth
t2
Postflow
Timer
ti
/Y
Preflow
Timer
S
Seconds
On Off
Positive
Negative
Alternating
Current
Gas
Input
Gas
Output
Rated
Welding
12
Current
Duty
Cycle
Direct
Current
~J
~
Line
Connection
Li2
Conventional
Load
Voltage
U1
Primary Voltage
I p
Degree
Of
Protection
Rated
Maximum
I~
max
Supply
Current
Maximum
Effective
eff
Supply
Current
U
~
Rated
No Load
Voltage (Average)
J]J]~
Pulse
Background
Amperage
~f~\
Initial
Amperage
()
Increase/Decrease
Of
Quantity
Normal
Trigger
JL
Operation
(GTAW)
;
$
Two-Step
Trigger
JX
Operation (GTAW)
Four-Step
Trigger
f\!
Operation
(GTAW)
Percent
Hz
Hertz
Recall
From
Memory
Arc Force
(DIG)
Impulse
Starting
(GTAW)
Final
Slope
Final
Amperage
Pulse
Percent
On
Time
Initial
Slope
~i~
I
Contactor Control
(Stick)
Q
J U L
Pulser
On-Off
A
TIG
Weld
Amps
And Peak
Amps
While
Pulsing
Pulse
Frequency
OM-2218
Page
ii

3-1.
Specifications
SECTION
3-
OPERATION
3-2.
Duty
Cycle
And
Overheating
-~
Rated
Output
at
60%
Duty Cycle
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
Amperes Input
At Rated
Output,
50Hz
-
Three-Phase
400
V
KVA
KW
Dimensions
Net
Weight
250
A
@
30
VDC,
60%
Duty Cycle
5

300 90
16.9
0.15*
11.7
0.10*
8.6
0.03*
H:
17
in
(432
mm)
W:
12-1/2
in
(318
mm)
D:
24 in
(610 mm)
82
lb
(37
kg)
~1Nhile
idling
.
4cc
2~
2cc
Duty Cycle
is
percentage
of
10
minutes that unit
can
weld
at
rated
load without
overheating.
If
unit
overheats,
output
stops,
a
Help
message
is
displayed (see
Section
5-3),
and
cooling
fan
runs.
Wait fifteen minutes for unit
to
cool.
Reduce
amperage
or
voltage,
or
duty
cycle
before
welding.
A
-~
20 25 ~Q
Exceeding
duty cycle
can
damage
unit and
void
warranty.
X
DJTY CYDE
40
250
A
@60%
Duty Cycle
Overheating
6
Minutes
Welding
4
Minutes
Resting
AorV
ST-186
863
OM-2218
Page
12

3-3.
Volt-Ampere
Curves
80
Cr)
F
d
>
40
20
0
Volt-ampere
curves
show
mini
mum
and
maximum
voltage
and
amperage
output
capabilities
of
welding
power
source.
Curves
of
other
settings
fall between
curves
shown.
ST-186
864
0 50
1~cl
200
250
ANPEF~S
~cc~ 3~ 400
3-4.
Selecting
A
Location
OM-2218
Page
13

3-5.
Weld
Output
Terminals And
Selecting
Cable
Sizes
.
~I~J
Welding
Amperes
Total Cable
(Copper) Length
In
Weld
Circuit
Not
Exceeding
100ff
(30
m)
Or
Less
150ff
(45
m)
200ft
(60
m)
250ff
(70
m)
300ft
J_(90_m)
350ft
(105
m)
400ft
(120 m)
1060%
Duty
Cycle
60100%
Duty
Cycle
10

100%
Duty
Cycle
Weld
Output
Terminals
+
Output
Receptacles
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
350
1/0
2/0
3)0 4/0
2-2/0
2-3/0
2-3/0
2-4)0
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.
S-0007-D
3-6.
Remote
14
Receptacle
Information
REMOTE
14
Socket*
A
Socket
Information
Contactor
control
24 volts dc.
/
~
~
ST-8O1
192-A
24
VOLTS DC
~
OUTPUT
CONTACTOR
B
Contact closure
to
A
completes
24
volts dc
contactor
control circuit
and enables
output.
REMOTE
OUTPUT
CONTROL
C
Output
to
remote
control;
0
to
+10
volts
dc
output
to
remote
control.
D
Remote control circuit
common.
E
0
to
+10 volts
dc
input
command
signal
from
remote
control.
A/V
AMPERAGE
VOLTAGE
F
Current
feedback;
+1
voltdc
per
100
amperes.
H
Voltage
feedback;
+1 volt
dc
per
10
output
receptacle
volts.
GND
K
Chassis
common.
*The
remaining
sockets
are
not
used.
OM-2218
Page
14

3-7.
Remote
4
Receptacle
Information
3-8. 115
Volts
AC
Duplex
Receptacle
Circuit
breaker
(Optional),
And Power
Switch
3-9.
Electrical Service Guide
Input Voltage
400
Input Amperes
At Rated
Output
16.9
Max Recommended
Standard
Fuse Or Circuit Breaker
Rating
In
Amperes
25
Mm
Input
Conductor Size
In
AWG/Kcmil
14
Max Recommended
Input
Conductor
Length
In
Feet
(Meters)
153
(47)
Mm
Grounding
Conductor
Size
In
AWG/Kcmil
14
Reference:
1996 National Electrical
Code
(NEC).
S-0092J
REMOTE 4
Socket*
Socket Information
A Contactor control
24 volts
dc.
24
VOLTS DC
G,
OUTPUT
CONTACTOR
B Contact closure
to
A
completes
24
volts dc
contactor
control circuit
and
enables
output.
ST-801
192-A
3~c~T~iI~2
_____'
b_
_
1 115 V 7
A AC
Receptacle
2
Circuit
Breaker
CB1
CB1
protects
duplex receptacle
from overload.
Press
button
to reset
breaker.
3
Power
On/Off
Switch
) I
0
0
Ref. ST-801
866
OM-2218
Page
15

3-10.
Connecting
Input
Power
.
OM-2218
Page
16