Miller XMT 300 CC/TIG User manual

/1
Miller
November
1995
Form:
OM-2204F
Effective
With
Serial
No.
KGO1
7632
OWNERS
MANUAL
.1

Read
and
follow
these instructions and all

Give
this manual
to
the
operator.


safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.


For
help,
call
your
distributor

or:
MILLER
Electric
Mfg.
Co.,
RO. Box
1079,
Appleton,
WI
54912 414-734-9821
XMTfi
300
CC/hG

CC/DC
Welding
Power Source

For
GTAW,
GTAW.P,
And
SMAW
Welding

300
Amperes,
32 Volts
DC
At
60%
Duty
Cycle

Uses
Single-Phase
Or Three-Phase
Input
Power

Protection
For Control
Circuit,
24
VAC,
And
Overheating

AUTO.LINKTM
Circuitry
And Built-In
High Frequency

14-Pin
Remote
Control
Receptacle

For
Options
And
Accessories,
See Rear
Cover
cover
5/94
-
ST-146
123-A
'
1995
MILLER
Electric
Mtg.
Co.
PRINTED
IN
USA

l
MILLERS
TRUE
BLUETM LIMITED
WARRANTY
Effective
January
1,1995
(Equipment
with
a
serial number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER warranties and is exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
1.
LIMITED WARRANTY

Subject
to
the
terms
and conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date of this limited
warranty
is
free of
de
fects
in
material
and
workmanship
at
the time it is
shipped
by
MILLER. THIS
WAR
RANTY IS
EXPRESSLY
IN
LIEU OF
ALL
OTHER
WARRANT1ES,
EXPRESS OR
IMPLJED,
INCLUDING
THE
WARRAN11ES OF MERCHANTABILITY AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
thaI
fail
due
to
such defects
in
material
or
workmanship.
MILLER
must
be notified in
writing
within
thirty
(30)
days
of such
defect
or
failure,
at
which
time
MILLER will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall honor
warranty
claims
on
warranted
equipment
listed below in the
event
of
such
a
failure
within the
warranty
time
periods.
All
warranty
time
peflods
start
on
the
date that the
equipment
was
delivered
tome
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North American distributor
or
eighteen
months
after the
equipment
is
sent to
an
International
distributor.
1. 5
Years Parts
3
Years
Labor

Original
main
power
rectifiers
*
Inverters
(input
and
output
rectifiers
only)
2. 3 Years

Parts
and
Labor

Transforrner/Roctffier Power Sources

Plasma
Arc
Cutting
Power Sources
Semi-Automatic
and Automatic Wire
Feeders

Inverter
Power
Supplies

Intellitigs

Robots
3.
2
Years

Parts and Labor

Engine
Driven
Welding
Generators
(NOTE: Engines
are warranted
separately by
the
engine
manufacturer.)

Air
Compressors
4.
1
YearPartsand
Labor
*
Motor
Driven
Guns

Process Controllers
IHPS
Power
Sources
Water
Coolant
Systems

HFUnits

Grids

Spot
Welders

Load Banks

SDX
Transformere
Running
Gear/Trailers

Plasma
Cutting
Torches
(except
APT,
ZIPCUT &
PLAZCUT
Models)
*
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered under True
BIueTM
for
the
remaining
wsrrsnty
period
of
the
product
they
are
installed
in,
or
for
a
minimum of
one
year

whichever
is
greeter.)
5.
6
Months

Batteries
1_________
6.
90
Days

Parts and
Labor
MIG Guns/flG
Torches

APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
*
Remote
Controls

Accessory
Kits

Replacement
Parts
MILLERS
True
BIue~
Umited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but manufaclured
by
others,
such
as
engines
or
trade accessories.
These items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactora
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has been
modified
by any
party
other than
MILLER,
or
equip
ment
that
has been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which has
not
had
reasonable
and
necessary
maintenance, or
equipment
which has been used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE INTENDED FOR PURCHASE
AND
USE BY COMMER
CIALI1NDUSTRIAL
USERS
AND
PERSONS
TRAINED AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE OF WELDING EQUIPMENT.
In
the
event
of
a
warranty
claim covered
by
this
warranty,
the exclusive remedies
shall
be,
at
MILLERS
option:
(1)
repair,
or
(2)
replacement;
or,
where authorized
in
writing by
MILLER
in
appropriate
cases,
(3)
the
reasonable
coat
of
mpairor replace
ment at
an
authorized
MILLER service
station;
or
(4)
payment
of
orcredit
torthe
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk and
expense.
MILLERS
option
of
repair
or
replacement
will be
FOB.,
Factoryat Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER. Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind will be allowed.
TO
ThE EXTENT
PERMITTED BY
LAW,
THE REMEDIES
PROVIDED
HEREIN
ARE THE SOLE
AND
EXCLUSIVE REMEDIES.
IN
NO
EVENT SHALL MILLER BE
UABLE FOR
DIRECT,
INDtRECT, SPECIAL
INCIDENTALOR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER BASED ON
CON
TRACT,
TORT OR
ANY
OTHER LEGAL THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND ANY IMPUED WAR
RANTY,
GUARANTY
OR
REPRESENTATiON AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH OF
CONTRACT TORT OR
ANY
OTHER LEGAL
THEORY
WHICH,
BUT FOR
THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATiON,
OPERA11ON OF
LAW,
CUSTOM OF TRADE OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY OF
MERCHANTABILITY
OR FITNESS
FOR PARTICULAR
PURPOSE,
WiTH
RESPECTTO
ANY
AND
ALL
EQUIPMENT
FURNISHED BY
MILLER
IS EXCLUDED
AND DISCLAIMED
BY
MILLER.
Some
states
in the
U.S.A.
do
not
allow
limitations
of how
long
an
implied
warranty
lasts,
or
the
exclusion
of incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
10
you.
This
warranty
provides
ape
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state to state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional warranties
or
remedies other
man as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the limitations
and exclusions
set
out
above
may
not
apply.
This
LImited
Warranty provides
specific
legal ngtrts,
and
other
rights
may
be
available,
but
may
,~,,vary
from
province
to
province.
r.
RECEIVING-HANDLING
Before
unpacking equipment,
check
carton
for
any
damage
that
may
have occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance for
filing
or
settling
claims
may
be obtained
from distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Numberof
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
__________
Serial
or
Style
No,
Date of Purchase
miller
6/95

ARC WELDING
SAFETY
PRECAUTIONS
ELECTRIC SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal shocks
or
severe
burns.
The
electrode
and work circuit is
electncally
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.
1.
Do
not touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry insulating
mats
or covers
big
enough
to
prevent
any
physical
contact
with
the work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and local
codes.
6.
Always
verify
the
supply
ground

check and be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
ARC WELDING
can
be
hazardous.
terminal
in
disconnect
box
or
that cord
plug
is
connected
to
a
properly grounded
receptacle
outlet.
7.
When
making input
connections,
attach
proper
grounding
conductor
first

double-check connections.
8.
Frequently
inspect input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10. Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work cable.
13. Do
not
touch
electrode
if
you
are
in
contact
with the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
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.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
A~
WARNING
PROTECT
YOURSELF AND OTHERS
FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY.
PACEMAKER
WEARERS KEEP
AWAY
UNTIL
CONSULTING YOUR DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
cerLain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION, MAINTENANCE,
AND REPAIR WORK
PERFORMED
ONLY BY
QUALIFIED
PEOPLE.
15.
16.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG OR SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet fitted
with
a
proper
shade
of filter
to
protect
your
face
and
eyes
when
welding
or
watching (see
ANSI
Arc
rays
from
the
welding
process
produce
intense
Z49.1
and
Z87.1
listed
in
Safety
Standards).
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
processes
3.
Wear
approved safety glasses
with
side
shields.
can
damage hearing.
Chipping,
grinding,
and
welds
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
cooling
throw
oft
pieces
of
metal
or
slag.
and
glare;
warn
others
not to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
Use
approved
ear
plugs
or ear
muffs
if
noise level is
high.
material
(wool
and
leather)
and
foot
protection.

I
FUMES
AND
GASES
can
be hazardous
5.
Work
in
a
confined
space
only
if
it is well
ventilated,
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
Welding produces
fumes and
gases.
Breathing
watchperson nearby.
Welding
fumes
and
gases
can
displace
these
fumes
and
gases
can
be hazardous
to
your
air
and lower the
oxygen
level
causing
injury
or
death. Be
sure
health.
the
breathing
air is
safe.
6. Do
not
weld
in
locations
near
degreasing, cleaning,
or
spraying
Keep
your
head
out of
the fumes. Do
not
breathe
the fumes.
operations.
The
heat and
rays
of
the
arc can
react
with
vapors
to
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
form
highly
toxic and
irritating
gases.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
ventilation
is
poor,
use
an
approved air-supplied
respirator.
cadmium
plated
steel,
unless the
coating
is removed
from
the
Read the
Material
Safety
Data Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers instruction for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these elements
can
give
off
toxic
fumes
if
welded.
,
CYLINDERS
can
explode
if
damaged.
4.
Never
drape
a
welding
torch
over a
gas
cylinder.
Shielding
gas
cylinders
contain
gas
under
high
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
~
pressure.
If
damaged,
a
cylinder
can
explode.
Since
6. Never
weld
on
a
pressurized
cylinder

explosion
will
result.
J~~~
gas
cylind:rs
are
~
~ef~Iyfhe
welding
7.
Use
onlycorrectshielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them and
associated
parts
in
good
condition.
Protect
compressed
gas
cylinders
from
excessive
heat,
8.
Turn
face
away
from valve outlet when
opening cylinder
valve.
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
Install
cylinders
in
an
upright
position
by
securing
to a
stationary in
use
or
connected
for
use.
support
or
cylinder
rack
to
prevent
falling
or
tipping.
10.
Read
and
follow instructions
on
compressed
gas
cylinders,
Keep
cylinders
away
from
any
welding
or
other
electrical
associatedequipment,andCGApublicationP-1
listedinSafety
circuits.
Standards.
srl.1.1
2/94

WELDING
can cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks, drums,
or
pipes,
can cause
them
to
blow
up.
Sparks
can
fly
off from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and hot
equipment
can
cause
fires
and
bums.
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.
1.
Protect
yourself
and others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld where
flying
sparks
can
strike
flammable
material.
3. Remove
all
flammables within 35
ft
(10.7 m)
of
the
welding
arc.
If
this is
not
possible, tightly
cover
them with
approved
covers.
4.
Be
alert
that
welding
sparks
and hot
materials from
welding
can
easily
go
through
small cracks
and
openings
to
adjacent
areas.
5.
Watch for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor, bulkhead,
or
partition
can
cause
fire
on
the
hidden side.
7.
Do
not
weld
on
closed containers
such
as
tanks, drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.1
(see
Safety
Standards).
8.
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.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10. Remove
stick
electrode
from holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
from
your person
before
doing
any
welding.
MOVING PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or covers
for
maintenance and
troubleshooting
as
necessary.
SPARKS
can cause
BATTERY GASES
TO
EXPLODE;
BATTERY ACID
can
burn
eyes
and
skin.
4.
To
prevent
accidental
starting
during servicing,
disconnect
negative
() battery
cable from
battery.
5.
Keep
hands, hair,
loose
clothing,
and
tools
awayfrom
moving
parts.
6.
Reinstall
panels
or
guards
and close doors when
servicing
is
finished
and
before
starting engine.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
1.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
and 3.
2.
Wear
safety glasses
and
gloves
and
put
a
rag
over
cap.
3.
Turn
cap
slightly
and
let
pressure escape
slowly
before
completely
removing
cap.
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,
Ameri
can
Welding
Society
Standard
AWS F4.1 from
American
Welding
So
ciety,
550
N.W.
Le.Jeune
Rd,
Miami,
FL
33126
National Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
srl.1.1
2/94
Safe
Handling
of
Compressed
Gases in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
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
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
SafePracticesForOccupationAndEducationalEyeAndFaceProtec
tion,
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.
4~
WARNING
ENGINES
can
be
hazardous.
j
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
produce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
ENGINE FUEL
can
cause
fire
or
3.
Do
not
overfill tank

allow
room
for fuel
to
expand.
explosion.
4.
Do
not
spill
fuel.
If fuel
is
spilled,
clean
up
before
starting
A
Engine
fuel
is
highly
flammable.
engine.
1.
Stop
engine
and let it cool
off before
checking
or
adding
fuel.
2.
Do
not
add
fuel
while
smoking
or
if
unit is
near
any
sparks
or
open
flames.
Moving
parts,
such
as
fans,
rotors,
and belts
can
cut
fingers
and hands
and
catch
loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
2.
Stoo
ena~ne
before
installing
or
connecting
unit.
1.
2.
Batteries contain acid
and
generate
explosive
gases.
Always
wear a
face
shield when
working
on a
battery.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
4.
5.
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
skin.
It is best
to
check
coolant level when
engine
is cold
to
avoid
scalding.

EMF INFORMATION
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2-2.
Duty Cycle
SECTION
3
INSTALLATION
3-1.
Typical
Process
Connections
3-2.
Selecting
A
Location
And
Moving
Welding
Power
Source
3-3.
Selecting
And
Preparing
Weld
Output
Cables
3-4.
Connecting
To
Weld
Output Receptacles
3-5.
Remote
14
Receptacle
RC2 Information
And
Connections
3-6.
Installing
Gas
Supply
3-7.
Connecting
Input
Power
SECTION
4
OPERATION
9
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
5-2.
Removing
Case
And
Measuring
Input
Capacitor
Voltage
5-3.
Overload
Protection
5-4.
Changing
AmperageNoltage
Meter Hold
Function
5-5.
Troubleshooting
SECTION
6-
ELECTRICAL
DIAGRAMS
20
SECTION
7-
HIGH
FREQUENCY
24
SECTION
8-
TUNGSTEN
ELECTRODE
8-1.
Selecting
Tungsten
Electrode
8-2.
Preparing
Tungsten
SECTION
9
PARTS
LIST
28
Figure
9-1.
Main
Assembly
(208-230/460V
Model
Illustrated)
28
Figure
9-2.
Chassis,
Mid
(208-230/460V
Model
Illustrated)
30
Figure
9-3.
Panel,
Front
w/Components
33
OM.2204F-
11195
NOTE
~
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 Paper,
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
interpret
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
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
AbOUt
Pacemakers;
The above
procedures
are
among
those also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor for
complete
information.
modlO.1
4/93
1
2
2
3
3
4
5
6
6
7
8
15
15
16
17
18
18
26
26
27

SECTION
1
-
SAFETY INFORMATION

Read
all
safety
messages
throughout
this manual.

Obey
all
safety
messages
to
avoid
injury.

Leam
the
meaning
of WARNING
and
CAUTION.
modl.1 2/93
;1~II~eU
K
can
kill
3
I
scat
parts.
power
beforeJj_
4
~r~!i!t~
ELECTRIC
SHOC

Do
not
touch
live
elect

Disconnect
input
installing
or
servicing.
Figure
1-1.
Safety
Information
SECTION 2-
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specification
Description
Type
Of
Output
Constant CurrentiDirect
Current
(CC/DC)
Welding
Processes Gas
Tungsten
Arc
(GTAW),
Gas
Tungsten
Arc
-
Pulsed
(GTAW-P),
Shielded
Metal Arc
Welding
(SMAW)
Input
Power
Cord
12
ft
(3.7
m)
Overall
Dimensions
Length:
21-3/4
in
(522
mm);
Width:
12 in
(305
mm);
Height:
17-3/8
in
(441
mm)
Weight
Rated
Weld
Output
Net:
84
lb
(38
kg);
Ship:
89 lb
(40
kg)
With
Three-Phase
Input
With
Single-Phase
Input
300
Amperes,
32
Volts
DC At
60%
Duty
Cycle
(See
Section
2-2)
225
Amperes,
29
Volts
DC
At
60%
Duty
Cycle
(See
Section
2-2)
Type
Of
Input
230, 460,
Or
575
Volts
AC;
50/60
Hz
230,
460,
Or
575
Volts
AC;
50/60
Hz
Input
Amperes
At Rated
Output
42
A
At
230
V,
21
A
At
460
V,
16.4
A
At
575
V
50.8
A
At 230
V,
29 A At
460
V,
23.6 A
At
575
V
Input
Amperes
While
Idling
(Fan
Not
Running)
1.2 A
At
230
V,
0.6
A
At
460
V,
0.6
A
At
575
V
1.1
A
At
230
V,
0.6
A
At
460
V,
0.6 A At
575
V
KVA/KW
Used At
Rated
Output
16.1 kVA/1
1.3 kW
12.8
kVA/7.8
kW
Amperage
Range
5-375 A
5-225
A
Max.
Open-Circuit
Voltage
80 Volts
DC
80
Volts
DC
1
2
2
\
/
AA
CAUTION
5
L
~
MOVING
PARTS
can
injure.

Keep
sway
from
moving parts.
I

Keep
all
panels
end
covers
closed
I
when
operating.
I
1
Safety
Alert
Symbol
2
Signal
Word
WARN
ING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
6
__!.
NOTE
~
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
Turn Off
switch
when
using
high frequency.
4
Safety
Instructions To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation

not
related
to
safety.
OM-2204
Page
1

SECTION 3-INSTALLATION
4~
WARNING
HIGH-FREQUENCY
RADIATION
can
interfere with radio
navigation,
safety
services,
computers,
and
communications
equipment.

Have
only qualified
person
famitiar
with
electronic
equipment
perform
this
installation.

Read and
follow
entire
Section
7
for
proper
location and
installation
requirements
for
high-frequency
equipment
before
unit.
swaml3.1
4/93
Figure
3-1.
Typical
Process
Connections
3-1.
Typical
Process
Connections
Work
+
GTAW
Pulse
Control
Scratch
Start
Pulsed
GTAW
Or
GTAW
+
+
OM-2204
Page
3

3-2.
Selecting
A
Location And
Moving
Welding
Power
Source
£~
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electncal
parts.

Disconnect
input
power
conductors
from de
energized
supply
line
BEFORE
moving welding
power
source.
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on, over,
or
near com
bustible
surfaces.

Do
not
locate unit
on, over,
or
near
combustible
surfaces.

Do
not
install unit
near
flammables,
BLOCKED
AIRFLOW
causes
over
heating
and
possible
damage
to
unit.

Do
not
block airflow.

Use
only
factory-approved
filter.
Warranty
is
void if
any
unapproved
filter
is
used.
FALLING
EQUIPMENT
can cause
serious
personal
injury
and
equipment
damage.

Lift
unit
at
handles.

Have
two
persons
of
adequate physical
strength
lift
unit.

Move unit with
hand
cart
or
similar
device
of ade
quate
capacity.

If
using
a
fork
lift
vehicle,
secure
unit
on
a
proper
skid
before
transporting.
swamll.1
12/94
FUMES
can
be
hazardous;
LACK OF
FRESH
AIR
AND
PROPER
TILATION
can
be
harmful.

Do
not
breathe
welding
fumes.

Place unit
only
where there is
a
good
supply
and
proper
ventilation.
VEN
fresh
air
Movement
Location
And
Airflow
3
in
(78
mm)
3
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
determine
input
power
needs.
4
Line
Disconnect
Device
Locate
unit
near correct
input
pow
er
supply.
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present

see
NEC
Article 511
or
CEC
Section
20.
ssb9.15194
-ST-146
123-A/Ref.
ST.151 556
6
in
(156
mm)
3
in
mm)
Figure
3-2.
Location
And Movement
Of
Welding
Power
Source
OM-2204
Page
4