Hobart CYBERTIG 250 User guide

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OM-359 196 831A

March 2001

Processes

TIG (GTAW) Welding

Stick (SMAW) Welding

Description

Arc Welding Power Source

CYBERTIG 250

Visit our website at

www.HobartWelders.com

And Non-CE Models

From Hobart to You

Thank you and congratulations on choosing Hobart. 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.

This Owner’s Manual is designed to help you get the most out of your Hobart 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 Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit

Hobart is registered to the ISO 9001 Quality System Standard.

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.

Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Y our distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

WARNING

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

25249.5 et seq.)

The following terms are used interchangeably throughout this manual: TIG = GTA W 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 UTILISA TION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Symbols And Definitions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Selecting A Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions And Weights 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Duty Cycle And Overheating 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Volt-Ampere Curves 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Weld Output Terminals And Selecting Cable Sizes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Remote 14 Receptacle Information 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Automation 10-Pin Connection (Optional) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle 17. . . . . . . . . . . . . . . . . . . . .

3-10. TIG Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) 18. . . . .

3-12. Front Panel Display For TIG AC 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Stick Connections 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 24. . . . . . . . . . . . . . .

3-15. Front Panel Display For Stick AC 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Electrical Service Guide 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17. Placing Jumper Links And Connecting Input Power 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Output Selector Switch 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Process Control 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Amperage Control 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Output Control 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional

Sequence Controls) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control 38. . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Selecting TIG Starting Characteristics 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Start Mode 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Meters 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Amperage Adjustment Control 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Balance/DIG Control 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Preflow Time Control 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Postflow Time Control 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15. Pulse Controls (Optional) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16. High Frequency Control 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17. Sequence Controls (Optional) 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-18. Initial Time Control And Initial Amperage Control 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19. Final Slope Control And Final Amperage Control 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Continued)

TABLE OF CONTENTS

4-20. Spot T ime Control 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21. Timer/Cycle Counter 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-22. Resetting Unit To Factory Default Settings (All Models) 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Circuit Breaker CB1 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Adjusting Spark Gaps 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Voltmeter/Ammeter Help Displays 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Troubleshooting 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAM 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – HIGH FREQUENCY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Welding Processes Requiring High Frequency 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Incorrect Installation 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Correct Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR

AC WELDING 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 64

8-2. Preparing Tungsten Electrode For Welding 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Positioning The Torch 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Torch Movement During Welding 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Positioning Torch Tungsten For Various Weld Joints 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – STICK WELDING (SMAW) GUIDELINES 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – PARTS LIST 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

som _nd_4/98

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards.

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

repair this unit.

Y 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

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

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

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

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

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

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body.

power circuit and machine internal circuits are also

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.

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

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

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

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

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

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

OM-359 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

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

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

D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

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

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

OM-359 Page 2

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring – be sure power supply system is

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

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

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

closed and securely in place.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D 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.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D 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-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-359 Page 3

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the 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 operator 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-359 Page 4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

Y Identifie un message de sécurité particulier.

. Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

Y Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Au cours de l’utilisation, tenir toute personne à l’écart et plus par-

ticulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les

tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

D Ne jamais toucher les pièces électriques sous tension. D Porter des gants et des vêtements de protection secs ne comportant

pas de trous.

D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

D Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

D Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-

lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D Installer et mettre à la terre correctement cet appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D Toujours v érifier la terre du cordon d’alimentation – Vérifier et s’assu-

rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée fixer d’abord le conducteur

de mise à la terre approprié et contre-vérifier les connexions.

D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas

endommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce, la

terre ou une électrode provenant d’une autre machine.

circuits internes de l’appareil sont également sous

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal

avec la pièce à souder ou la table de travail, le plus près possible de l a soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

Il y a DU COURANT CONTINU IMPORT ANT dans les convertisseurs après la suppression de l’alimenta- tion électrique.

D Arrêter les convertisseurs, débrancher le courant électrique, et dé-

charger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer

D A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau

de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à alimenta-

tion d’air homologué.

D Lire les spécifications de sécurité des matériaux (MSDSs) et les

instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations de

dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l ’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

les fumées.

OM-359 Page 5

LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses

des brûlures dans les yeux et sur la peau. Des étincelles sont projetées

pendant le soudage.

D Porter un casque de soudage muni d’un écran de filtre approprié pour

protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair

et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

D Porter des vêtements de protection constitué dans une matière dura-

ble, résistant au feu (cuir ou laine) et une protection des pieds.

(ultraviolets et infrarouges) susceptibles de provoquer

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

D Ne pas toucher des parties chaudes à mains nues D Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être

les, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement o u u n incendie. A vant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Se protéger et d’autres personnes de la projection d’étincelles et de

métal chaud.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur

des substances inflammables.

D Déplacer toutes les substances inflammables à une distance de 10,7

m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D Des étincelles et des matériaux chauds du soudage peuvent facile-

ment passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-

mité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que des

réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

D Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’élec- trocution et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans re- vers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos poches

telles qu’un allumeur au butane ou des allumettes.

projetées de l’arc de soudure. La projection d’étincel-

DES PARTICULES VOLANTES peuvent blesser les yeux.

D Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

lantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

des étincelles et des particules métalliques vo-

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs d e stimulateur cardiaque, restez à distance. D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz

manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, du laitier, des flammes ouvertes, des étin- celles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnai-

re ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits d e soudage ou autres cir-

cuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une

bouteille.

D Ne jamais souder une bouteille pressurisée – risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

D Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-

lisation ou de branchement de la bouteille.

D Lire et suivre les instructions concernant les bouteilles de gaz com-

primé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.

font normalement partie du procédé de soudage, les

OM-359 Page 6

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou à proxi-

mité de surfaces infllammables.

D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique – s”assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D Utiliser l’anneau de levage uniquement pour sou-

lever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un engin d’une capacité appropriée pour

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

soulever l’appareil.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement, respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

D Ne pas obstruer les passages d’air du poste.

recommancer le soudage.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Rester à l’écart des organes mobiles comme le

ventilateur.

D Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

D Le rayonnement haute frequence peut provoquer

des interférences avec les équipements de radio–navigation e t d e communication, les services

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa- tion.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appa-

reil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interfé- rences éventuelles.

de sécurité et les ordinateurs.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres person-

nes ou toute pièce mécanique en engageant le fil de soudage.

D L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement

D Veiller à ce que tout l’équipement de la zone de soudage soit com-

patible électromagnétiquement.

D Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

D Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précédentes, il

incombe à l’utilisateur de prendre des mesures supplémentaires tel- les que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

commandé par ordinateur tel que les robots.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’appro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points.

OM-359 Page 7

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American 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 Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l ’American Welding Society , 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFP A 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur , il est alors recommandé de respecter les consignes ci–dessus.

OM-359 Page 8

SECTION 2 – DEFINITIONS

2-1. Warning Label Definitions

1 1.1 1.2

3 3.1 3.2 3.3

4 4.1

2.1

2.2

2.3

1.3

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. Don’t weld near flammables.

3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person 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.

5 6

S-176 254-A

OM-359 Page 9

2-2. Symbols And Definitions

NOTE

A V

Some symbols are found only on CE products.

Amperes Panel–Local

Volts

Output Circuit Breaker Remote Temperature

Protective Earth

(Ground)

Postflow Timer Preflow Timer

Gas (Supply) Gas Input Gas Output

On Off Percent Direct Current

Do Not Switch While Welding

Alternating Current

Gas Tungsten Arc

Welding (GT AW)

Arc Force (DIG) Background Amps

High Frequency -

Start

High Frequency -

Continuous

Shielded Metal Arc

Welding (SMAW)

High Frequency

Increase/Decrease

Of Quantity

Input

Balance Control Maximum Cleaning

Electrode

Negative

Voltage (A verage)

Rated No Load

Primary Current

Degree Of Protection

Electrode Work Thickness Gauge Spark Gap

Seconds Final Amperage Initial Time Initial Amperage

1eff

Maximum

Penetration

Final Slope Meter Single-Phase

Primary Voltage

Rated Welding

Current

Maximum Effective

Supply Current

1max

Conventional Load

Rated Maximum

Supply Current

Voltage

Duty Cycle

Electrode Positive

Line Connection

Single-Phase

Combined AC/DC

Power Source

Hertz

OM-359 Page 10

Pulse Percent On

Time

Trigger Hold Pulser On-Off Pulse Frequency

Spot Time Lift-Arct

4 Step Trigger Op-

eration Sequence

SECTION 3 – INSTALLATION

3-1. Selecting A Location

Movement

Y Falling Unit Can Cause

Injury.

S Use lifting eye to lift unit only,

NOT running gear, gas cylinders, or any other accessories.

S Use equipment of adequate

capacity to lift and support unit.

S If using lift forks to move unit,

be sure forks are long enough to extend beyond opposite

side of unit. 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to

move unit. If using lifting forks, extend forks

beyond opposite side of unit. 3 Rating Label Use rating label to determine input

power needs. 4 Line Disconnect Device Locate unit near correct input pow-

er supply.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 2 0 . Y Be careful when placing or

moving unit over uneven

surfaces.

Location A n d A i r f l o w

18 in (460 mm)

Ref. ST-117 264-C / ST-802 455-B

OM-359 Page 11

3-2. Dimensions And Weights

Front

H 8 Holes

Ref. ST-196 584-B

Height 34 in (864 mm)

Width 22-1/2 in (572 mm)

Length 25 in (635 mm)

A 25 in (635 mm)

B 1-25/64 in (35 mm)

C 1-5/8 in (41 mm)

D 20-5/8 in (524 mm)

E 19-15/16 (506 mm)

F 22-1/4 (565 mm)

G 1-5/32 in (30 mm)

H 1/2 in (13 mm) Dia

Dimensions

Weight

389 lbs (176 kg)

3-3. Specifications

Rated

Welding Output

NEMA Class I (40) –

200 Amperes, 28

Volts AC, 60% Duty

Cycle

NEMA Class I (40) –

200 Amperes, 28

Volts AC, 60% Duty

Cycle

NEMA Class II (40) –

250 Amperes, 30

Volts AC, 40% Duty

Cycle

NEMA Class II (40) –

250 Amperes, 30

Volts AC, 40% Duty

Cycle

*While idling **Power Factor Correction

PFC**

PFC

With PFC

PFC

With PFC

Amperes Input at AC Balanced Rated

Load Output, 60 Hz, Single-Phase

200V 230V 460V 575V

*3.3

*55.3

110

*3.3

*55.3

*2.8

*49.5

*2.8

*49.5

*1.5

*24.5

*1.5

*24.5

*1.1

*19.6

*1.1

*19.6

KVA KW

17.6

*.59

12.06 *11.2

21.98 *.59

16.32

*11.2

8.6

*.29

8.11 *.39

11.76 *.29

11.81

*1.93

Amperage

Range

5 – 310A 80V

Max

OCV

OM-359 Page 12

3-5. Specifications(continued)

Amperes Input at AC Balanced Rated

Load Output, 50/60 Hz, Single-Phase

Rated

Welding Output

NEMA Class I (40) –

200 Amperes, 28

Volts AC, 60% Duty

Cycle

NEMA Class I (40) –

200 Amperes, 28

Volts AC, 60% Duty

Cycle

NEMA Class II (40) –

250 Amperes, 30

Volts AC, 40% Duty

Cycle

NEMA Class II (40) –

250 Amperes, 30

Volts AC, 40% Duty

Cycle

*While idling **Power Factor Correction

Rated

Welding Output

NEMA Class I (40) –

175 Amperes, 27

Volts AC, 60% Duty

Cycle

NEMA Class I (40) –

175 Amperes, 27

Volts AC, 60% Duty

Cycle

NEMA Class II (40) –

225 Amperes, 29

Volts AC, 40% Duty

Cycle

NEMA Class II (40) –

225 Amperes, 29

Volts AC, 40% Duty

Cycle

*While idling **Power Factor Correction

PFC**

PFC

With PFC

PFC

With PFC

PFC**

PFC

With PFC

PFC

With PFC

220V 400V 440V 520V

*3.0

*45.9

100 *3.0

*45.9

*1.6

*25.1

*1.6

*25.1

*1.4

*22.8

*1.4

*22.8

*1.2

*23.2

*1.2

*23.2

Amperes Input at AC Balanced Rated

Load Output, 50 Hz, Single-Phase

200V 230V 460V 575V

*3.3

*55.3

101 *3.3

*55.3

*2.8

*49.5

*2.8

*49.5

*1.5

*24.5

*1.5

*24.5

*1.1

*19.6

*1.1

*19.6

KVA KW

17.6

*.59

12.06 *11.2

21.98 *.59

16.32

*11.2

8.6

*.29

8.11 *.39

11.76 *.29

11.81

*1.93

KVA KW

15.9

*.59

10.3

*11.2

20.2

*.59

14.7

*11.2

7.4

*.29

7.3

*.39

10.2 *.29

10.1

*1.93

Amperage

Range

5 – 310A 80V

Amperage

Range

5 – 310A 80V

Max

OCV

Max

OCV

OM-359 Page 13

3-4. Duty Cycle And Overheating

Duty Cycle is the percentage of 10 minutes that the unit can weld at rated load without overheating.

If unit overheats, output stops, front panel voltmeter/ammeter displays a HLP3 or HLP5 message (see Section 5-4), and cooling fans run. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

Y Exceeding duty cycle can

damage unit and void warranty.

40% Duty Cycle At 250 Amperes

4 Minutes Welding 6 Minutes Resting

Overheating

3-5. Volt-Ampere Curves

Minutes

60% Duty Cycle At 200 Amperes

6 Minutes Welding 4 Minutes Resting

Reduce Duty Cycle

duty1 4/95 / SB-116 198

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

OM-359 Page 14

ssb1.1 10/91 – 194 385-A / 194 384-A

3-6. Weld Output Terminals And Selecting Cable Sizes

Y ARC WELDING can cause Electromagnetic Interference.

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

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

Weld Output

Terminals

Work

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

Electrode

Ref. ST-801 972

Welding

Amperes

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

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

10 – 60%

Duty

Cycle

60 – 100%

Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 – 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

3-7. Remote 14 Receptacle Information

*The remaining sockets are not used.

ST-801 972

24 VOLTS DC

REMOTE

OUTPUT

CONTROL

AMPERAGE

VOLTAGE

OUTPUT CONTACTOR

A/V

GND

Socket* Socket Information

A Contactor control 24 volts dc.

B Contact closure to A completes 24 volts dc

contactor control circuit and enables output.

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

to remote control.

D Remote control/feedback circuit common. E 0 to +10 volts dc input command signal from

remote control.

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

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

K Chassis common.

OM-359 Page 15

3-8. Automation 10-Pin Connection (Optional)

Socket Socket Information For 10-Pin Receptacle RC2

A Start/Stop

B Gas

C Output disabled

D Chassis ground

E Final slope – collector

F Final slope – emitter

G Pulse lockout – collector

Ref. ST-801 972

A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100ms, but less than 3/4 seconds) starts and stops weld output.

B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initiation.

C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to time out, and HELP 13 will be displayed on the meters.

Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30 VDC.

Final Slope - output is on when in Final Slope.

Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10 Hz.

Arc On - output is on when the contactor is on and there is less than 50 load volts.

H Pulse lockout – emitter

I Valid arc – collector

J Valid arc – emitter

Definitions Of Inputs And Outputs

Inputs

Outputs

OM-359 Page 16

3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle

Y Turn Off power before con-

necting t o receptacle.

1 Gas Valve In Fitting Located on rear of unit. 2 Gas Valve Out Fitting Fittings have 5/8-18 right-hand

threads. 3 Cylinder Valve Open valve slightly so gas flow

blows dirt from valve. Close valve. 4 Regulator/Flow Gauge Connect regulator/flow gauge to

gas cylinder. Connect customer supplied gas

hose between regulator/flow gauge and gas in fitting.

5 Flow Adjust Typical flow rate is 20 cfh (cubic feet

per hour). 6 115 V 15 Amp AC Receptacle Receptacle is protected from over-

load by circuit breaker CB1 (see Section 5-2).

Tools Needed:

5/8, 3/4, 1-1/8 in

Front View Rear View

3-10. TIG Connections

Ref. ST-801 972 / Ref. ST-801 973 / Ref. ST-157 858

1 Gas In Connection Connect gas hose from gas supply

to gas in fitting. 2 Output Selector Switch (See

Section 4-2)

Switch is shown in DCEN (direct current electrode negative) position for TIG HF Impulse DCEN welding. For front panel control dispay, see Section 3-11. For TIG AC welding, place switch in AC position (see Section 4-2). For TIG AC front panel control dispay, see Section 3-12.

3 Work Weld Output Terminal Connect work lead to work weld

output terminal. 4 Remote 14 Receptacle Connect desired remote control to

Remote 14 receptacle. 5 Electrode Weld Output

Terminal

Connect TIG torch to electrode weld outout terminal.

6 Gas Out Connection Connect torch gas hose to gas out

fitting.

Tools Needed:

11/16, (21 mm), 3/4 in

802 734-B

OM-359 Page 17

3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)

1 Front Panel Correct front panel display for basic

TIG HF Impulse DCEN welding.

. For all front panel switch pad

controls: press switch pad to turn on light and enable function.

NOTE: Green on nameplate indicates a TIG function (see Section 4-1 for description of controls).

OM-359 Page 18

CE Models

OM-359 Page 19

3-12. Front Panel Display For TIG AC

1 Front Panel Correct front panel display for basic

TIG AC welding.

. For all front panel switch pad

controls: press switch pad to turn on light and enable function.

NOTE: Green on nameplate indicates a TIG function (see Section 4-1 for description of controls).

OM-359 Page 20

CE Models

OM-359 Page 21

Notes

OM-359 Page 22

3-13. Stick Connections

1 Work Weld Output Terminal Connect work lead to work weld

output terminal. 2 Electrode Weld Output

Terminal

Connect electrode holder to electrode weld outout terminal.

3 Remote 14 Receptacle If desired, connect remote control

to Remote 14 receptacle.

4 Output Selector Switch (See

Section 4-2)

Switch is shown in DCEP (direct current electrode positive) position for Stick DCEP welding. For front panel control dispay, see Section 3-14. For Stick AC welding, place switch in AC position (see Section 4-2). For Stick AC front panel control dispay, see Section 3-15.

Tools Needed:

11/16, (21 mm), 3/4 in

802 733-B

OM-359 Page 23

3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

1 Front Panel Correct front panel display for basic

Stick DCEN welding.

. For all front panel switch pad

controls: press switch pad to turn on light and enable function.

NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls).

OM-359 Page 24

CE Models

OM-359 Page 25

3-15. Front Panel Display For Stick AC

1 Front Panel Correct front panel display for basic

Stick AC welding.

. For all front panel switch pad

controls: press switch pad to turn on light and enable function.

NOTE: Gray on nameplate indicates a Stick function (see Section 4-1 for description of controls).

OM-359 Page 26

CE Models

OM-359 Page 27

3-16. Electrical Service Guide

NOTE

All values in both tables were calculated at 60% duty cycle.

50/60 Hertz Models Without Power Factor Correction Input Voltage Input Amperes At Rated Output

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker

Time-Delay Fuse

Normal Operating (Fast) Fuse Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In

Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil

Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse. 2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

200 220 230 400 440 460 520 575

88 82 77 45 41 38 35 31

125 125 125 70 60 60 50 45

4 6 6 8 8 10 10 10

167

(51)

6 6 6 8 10 10 10 10

137 (42)

153 (47)

305

(93)

369

(112)

281

(86)

50/60 Hertz Models With Power Factor Correction

352

(107)

439

(134)

Input Voltage Input Amperes At Rated Output

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker

Time-Delay Fuse

Normal Operating (Fast) Fuse Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In

Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil

Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse. 2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

200 220 230 400 440 460 520 575

60 61 52 34 31 26 26 21

90 90 80 50 45 40 40 30

8 8 8 10 10 10 10 12

87 (26)

8 8 8 10 10 10 10 12

102 (31)

115 (35)

226 (69)

274

(84)

308

(94)

383

(117)

295 (90)

OM-359 Page 28

3-17. Placing Jumper Links And Connecting Input Power

230 VOLTS 460 VOLTS200 VOLTS

LL LL LL

230 VOLTS

460 VOLTS

S-083 566-C

575 VOLTS

S-010 587-B

Check input voltage available at site.

1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input

voltage. 3 Input And Grounding

Conductors

Select size and length using Section 3-16.

4 Line Disconnect Device Select type and size of overcurrent

protection using Section 3-16. Close and secure primary door.

Y Special installation may be

required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 2 0 .

Connect GND/PE Conductor First

GND/PE Earth Ground

L1 (U)

L2 (V)

3/8 in

Connect GND/PE Conductor First

Tools Needed:

Ref. ST-801 973-B

OM-359 Page 29

SECTION 4 – OPERATION

4-1. Controls

A. For 200/230/460 Volts And Non CE Units

1234

. Top row of lights in upper left corner are On

for SMAW. Bottom row are On for GTAW.

Green on nameplate indicates a TIG function, Gray indicates a Stick function.

1 Process Control See Section 4-3. 2 Amperage Control See Section 4-4. 3 Output Control See Section 4-5. 4 Start Mode Control See Section 4-9.

OM-359 Page 30

5 Voltmeter See Section 4-10 6 Ammeter See Section 4-10 7 Amperage Adjustment

Control See Section 4-11. 8 Output Selector Switch See Section 4-2. 9 Power Switch Use switch to turn unit Off and On.

10 Postflow Time Control See Section 4-14. 11 Balance/DIG Control See Section 4-12. 12 Pulser Controls (Optional) See Section 4-15. 13 Sequence Controls (Optional) See Section 4-17. 14 High Frequency Control See Section 4-16.

Ref. ST-196 616 / Ref. ST-194 388-B / Ref. ST-801 972

B. For CE Units

1234

. Top row of lights in upper left corner are On

for SMAW. Bottom row are On for GTAW.

Green on nameplate indicates a TIG function, Gray indicates a Stick function.

1 Process Control See Section 4-3. 2 Amperage Control See Section 4-4. 3 Output Control See Section 4-5. 4 Start Mode Control See Section 4-9.

5 Voltmeter See Section 4-10 6 Ammeter See Section 4-10 7 Amperage Adjustment

Control See Section 4-11. 8 Output Selector Switch See Section 4-2. 9 Power Switch Use switch to turn unit Off and On.

Ref. ST-196 764 / Ref. ST-196 766 / Ref. ST-801 972

OM-359 Page 31

4-2. Output Selector Switch

4-3. Process Control

1 Output Selector Switch

Y Do not use AC output in

(CE Nameplate)

damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control.

Y Do not change position of

switch while welding or while under load.

Use switch to select (DCEN) Direct Current Electrode Negative, AC, or (DCEP) Direct Current Electrode Positive output.

NOTE: Changing position of Output Selector switch may also change Process control, Current control, Output control, and Start Mode control settings to properly function with latest Output Selector switch setting.

4-4. Amperage Control

1 1

(CE Nameplate)

1 Process Control Use control to select Shielded Met-

al Arc Welding (SMAW) or Gas Tungsten Arc Welding (GTAW) process.

For SMAW, press button to toggle LED to Stick position.

For GTAW, press button to toggle LED to TIG position.

NOTE: Lit LED indicates selected

mode. When Output Selector switch posi-

tion changes, LED may change position, based upon last selection.

Ref. ST-196 616 / Ref. ST-196 764

1 Amperage Control Use control to select front panel or

remote amperage control. For front panel amperage control,

press button to toggle LED to Panel position.

For remote amperage control, press button to toggle LED to Remote position (see Section 3-7).

NOTE: Lit LED indicates selected mode.

When Output Selector switch position changes, LED may change position, based upon last selection.

OM-359 Page 32

Notes

OM-359 Page 33

4-5. Output Control

Remote (Standard)Torch Trigger Operation

Current (A)

Preflow

Initial Amps

(CE Nameplate)

Remote (Standard)Torch Trigger Operation

Weld Amps

Final Slope

Final Amps

Postflow

Push & Hold Foot Or Finger Remote Control

1 Output Control

Y Weld output terminals are ener-

gized when power is On, and Output On LED is lit.

Use control to select front panel, trigger hold, or remote output control.

NOTE: Lit LED indicates selected mode. For weld output, press button to toggle LED

to On position.

OM-359 Page 34

Release For Maintained Switch

2 Remote Trigger (Standard) Operation For remote output control, press button to

toggle LED to Remote position (see Section 3-7).

Torch trigger operation is as shown.

NOTE: Initial weld amperage and final amperage is controlled by the remote device, not by the welding power source.

Release Foot Or Finger Remote Control

NOTE: If On/Off only type trigger is used, it must be a maintained switch. All functions become active.

Application: Use Remote Trigger when the operator desires to use a foot pedal or finger amperage control.

When Output Selector switch (see Section 4-2) position changes, Output control LED will always switch to Remote.

When Output On is selected, HF and gas control are disabled.

Trigger Hold (2T)

Current (A)

Preflow

Initial Amps

(CE Nameplate)

2T Torch Trigger Operation

Weld Amps

Final Slope

Final Amps

Postflow

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

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

3 Trigger Hold For trigger hold operation, press button to

toggle LED to Trigger Hold position. Torch trigger operation is as shown.

NOTE: When a foot or finger remote control is connected to the welding power source, only trigger input is functional.

NOTE: Amperage is controlled by the

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

welding power source. Application: Use Trigger Hold (2T)

when long extended welds are made. Trigger Hold (2T) can help to reduce operator fatigue.

OM-359 Page 35

4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional Sequence

Controls)

4T Torch Trigger Operation

If unit is equipped with optional Sequence Controls (see Section 4-17), 4T trigger method is available.

4T torch trigger operation is as shown. While in 4T mode, there is a feature avail-

able during the main weld sequence that al-

Current (A)

Initial Amps

Preflow

Push & Hold Trigger

Release Trigger

lows the operator to toggle between weld current and final current without breaking the arc.

NOTE: When a remote switch is connected to the welding power source, only trigger input is functional. Amperage is controlled by the welding power source.

Weld Amps

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

Application:

Use 4T trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.

Select 4T trigger method according to Section 4-7.

Final Slope

Final Amps

Postflow

Push & Hold Trigger

Release Trigger

If unit is equipped with optional Sequence Controls (see Section 4-17), 4T Momentary trigger method is available.

4T Momentary torch trigger operation is as shown.

While i n 4 T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break the arc and go to postflow.

Current (A)

Initial Amps

Preflow

Push & Release Trigger

4T Momentary Torch Trigger Operation

NOTE: When a remote switch is connected to the welding power source, only trigger input is functional. Amperage is controlled by the welding power source.

Weld Amps

Push & Release Trigger

Application:

Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.

Select 4T Momentary trigger method according to Section 4-7.

Final Slope

Final Amps

Postflow

Push & Release Trigger

OM-359 Page 36

Mini Logic Operation

If unit is equipped with optional Sequence Controls (see Section 4-17), Mini Logic operation is available.

Torch trigger operation is as shown. During Mini Logic welding operation, the

weld amperage can be manually changed

Initial Amps

Preflow

Push & Hold Trigger

Push & Hold Trigger For More Than 3/4 Sec.

Final Slope Rate

from the initial amps level to the main weld amps level by pressing and releasing the torch trigger in less than 3/4 seconds.

NOTE: When a remote switch is connected to the welding power source, only trigger input is functional. Amperage is controlled by

Weld Amps

Initial Amps

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

the welding power source. Application: This ability to change amper-

age levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc.

Select Mini Logic according to Section 4-7.

Final Slope

Postflow

Push & Hold Trigger For More Than 3/4 Sec.

Release Trigger

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

OM-359 Page 37

4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control

1 Output Control 2 Power Switch To reconfigure Trigger Hold, turn Off

power, push and hold Output control button and turn On power switch. Hold button for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters display [SEL] [H–2].

Press Output control button to change functions. Active function will be displayed on amperage (bottom) meter.

3 Meter Displays Meter displays for the different func-

tions will be as shown. Press torch trigger or turn power Off

to save setting. Proceed t o Section 4-6 for 4T Opera-

tion. Proceed to Section 4-6 for Mini Logic

operation. Proceed to Section 4-6 for 4T Mo-

mentary operation. NOTE: These features are only

available when optional Sequencer is installed.

Front Panel

SEL

H-2

SEL

HĆ4E

4T Momentary

(See Section 4-6)

SEL

H-4

4T (See Section 4-6)

SEL

H4L

Mini Logic (See Section 4-6)

OM-359 Page 38

(CE Nameplate)

Front Panel

SEL

H-2

SEL

HĆ4E

4T Momentary

(See Section 4-6)

SEL

H-4

4T (See Section 4-6)

SEL

H4L

Mini Logic (See Section 4-6)

OM-359 Page 39

4-8. Selecting TIG Starting Characteristics

SEL

-2-

Use this function to select desired TIG starting characteristics.

1 Start Mode 2 Power Switch 3 Output Selector Switch 4 Meters To select or change TIG starting characteris-

tics, proceed as follows: turn Off power. Place Output Selector switch in desired position (each position, DCEN, AC, or DCEP has three applicable start characteristics op-

OM-359 Page 40

tions). Push and hold Start Mode button and turn On power. Hold button for approximately 7 seconds (or until software version number_ _ _ _ _ _-_ clears meters).

The TIG LED and all four Start LEDs will light, and the meters will display [SEL] [-2-].

Press Start Mode button again to step through the three start characteristics choices. Amperage (bottom) meter displays active choice 1= light start, 2=medium/normal start, 3=high/hot start.

Press torch trigger or turn Off power to save setting.

Application:

Select 1 (light/soft start) – when welding at low amperages on thin gauge material.

Select 2 (medium/normal start) – factory default setting used for most welding applications.

Select 3 (high/hot start) – when welding at high amperages on thick materials with a large diameter tungsten.

(CE Nameplate)

SEL

-2-

OM-359 Page 41

4-9. Start Mode

(CE Nameplate)

Lift-Arct Start Method

“Touch”

Do NOT Strike Like A Match!

1 – 2

Seconds

1 Start Mode For SMAW welding, press button to toggle

LED to Off position. For GTAW welding, use control to select

Off for no HF, Lift-Arct, HF for arc starting only , or continuous HF. See Section 4-16 for adjusting high frequency intensity.

Application:

When Off is selected, use the scratch method t o s t a r t a n arc for both the SMA W and GTAW processes.

When Lift-Arc is selected, start arc as follows:

2 TIG Electrode 3 Workpiece Touch tungsten electrode to workpiece at

weld start point, enable output with torch trigger, foot control, or hand control. Hold

electrode to workpiece for 1-2 sec-

OM-359 Page 42

onds, and slowly lift electrode. An arc will form when electrode is lifted.

Shielding gas begins to flow when electrode touc h e s w o r k p i e c e .

Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid state output contactor does not energize until after electrode is touching workpiece. Th i s a l l o w s electrode to touch workpiece without overheating, sticking, or getting contaminated.

Application:

Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.

When HF Start is selected, start arc as follows:

High frequency turns on to help start arc when output is enabled. High frequency

turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTAW process is required.

When HF Continuous is selected, start arc as follows:

High frequency turns on when output is energized and remains on for duration of weld.

Application:

HF Continuous is used when the AC GTA W process is required.

NOTE: Lit LED indicates selected mode. When Output Selector switch position

changes, LED may change position, based upon last selection.

NOTE: Some start methods may not be available for all processes.

4-10. Meters

4-11. Amperage Adjustment Control

(CE Nameplate)

1 Voltmeter Voltmeter displays average voltage

(to the nearest 0.1 V) at the weld output terminals.

2 Ammeter Use meter to preset amperage. Me-

ter displays average weld amperage output of unit to nearest ampere when welding.

NOTE: Meters are self-calibrating. No adjustment available.

1 Amperage Adjustment Control Use control to adjust amperage,

and preset amperage on ammeter (see Section 4-10). This control

may be adjusted while welding. For remote amperage control,

front panel control setting is the maximum amperage available. For example: I f front panel control is set to 200 A, the range of the remote amperage control is 5 to 200 A.

For pulse welding, use Amperage Adjust control to select from 5–300 amps of peak amperage (see Section 4-15).

For spot welding, use Amperage Adjust control to select from 5–300 amps of peak amperage (see Section 4-20).

OM-359 Page 43

4-12. Balance/DIG Control

Balanced

More Penetration

More Cleaning

1 1

Balance Control Examples

Output Waveforms

50% Electrode

Positive

50% Electrode

Negative

32% Electrode

Positive

68% Electrode

Negative

55% Electrode

Positive

45% Electrode

Negative

(CE Nameplate)

1 Balance/DIG Control

Balance Control (AC GTAW):

Control changes the AC output square wave. Rotating the control towards 10 prov i d e s d e e p e r p e n e tration. Rotating the control towards 0 provides more cleaning action of the workpiece.

When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action.

Application:

When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only a minimal amount, approximately a

ArcSetting

0.10 in (2.5mm) of etched zone along the weld toes is required.

Set control to 7 and adjust as necessary. Joint configuration, set-up, process variables, and oxide thickness may affect setting.

NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the Balance control towards maximum penetration, may help to restabilize the arc.

DIG Control (AC And DC SMAW):

When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage.

When setting is increased, shortcircuit amperage at low arc voltage increases.

Application:

Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding.

OM-359 Page 44

Ref. S-0795-A

Notes

OM-359 Page 45

4-13. Preflow Time Control

00.2

SEL

Use control to set length of time (0.2, 0.4, 0.6,

0.8, 1.0, 2.0 or 4.0 seconds) gas flows before welding starts.

1 Process Control 2 Power Switch 3 Meters To change preflow time, proceed as follows:

OM-359 Page 46

Turn power off. Push and hold Process Control button and turn On power. Hold button for approximately 7 seconds (or until software version number_ _ _ _ _ _-_ clears meters).

The TIG LED will light and the meters will display [o.2] [SEL]. The factory preflow default setting is 0.2 seconds. To change preflow

time, p r e s s and release Process Control button until desired time is displayed on meters.

Application:

Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

(CE Nameplate)

00.2

SEL

OM-359 Page 47

4-14. Postflow Time Control

(CE Nameplate)

1 Postflow Time Control Use control to set length of time

(0–50 seconds) gas flows after welding stops. It is important to s e t enough time to allow gas to flow un-

til after the tungsten and weld puddle has cooled down.

Application:

Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (approximately 1 second per 10 ampere of welding current).

OM-359 Page 48

4-15. Pulse Controls (Optional)

(CE Nameplate)

Percent (%) Peak

Time Control Setting

(50%)

Balanced

Peak Amp

More Time

At Peak

Amperage

More Time At

Background

Amperage

(20%)

(80%)

Pulsed Output Waveforms

PPS

Bkg Amp

1 On/Off Control

Use control to turn pulse function On and Off.

2 Background Amps Use Background Amps control to

set the low pulse of the weld amperage, which cools the weld puddle and affects overall heat input. Background Amps is set as a percentage of peak amperage.

3 Pulse Frequency Ranges from 0.25–10.0 pps

(pulses per second). Control is used to determine appearance o f weld bead.

4 Peak Time A range of 5–95% of each pulse

cycle can be spent at the peak amperage level.

Peak amperage (5–310 amps), is set with the Amperage Adjustment control (see Section 4-1). Peak amperage is the highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage.

5 Pulsed Output Waveforms Example shows affect changing

the Peak Time control has on the pulsed output waveform.

Application:

Pulsing refers to the alternating raising and lowering of the weld output at a specific rate. The raised por t io n s o f t h e w e l d o u t p u t are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level between them (called the background amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding.

Pulsing can also be used for filler material addition technique training.

NOTE: Function is enabled, when LED is lit.

OM-359 Page 49

4-16. High Frequency Control

Y Do not use high frequency while Shielded Metal Arc Weld-

ing (SMAW).

1 High Frequency Control For GTA W, use control to set HF intensity. Set as low as possible.

Application:

If HF is present at the tungsten, the control is set high enough.

4-17. Sequence Controls (Optional)

Ref. ST-801 972

NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the HF Intensity control towards maximum, may help to restabilize the arc.

. As high frequency intensity is increased, the possibility of inter-

fering with local electronic devices, especially communication equipment, also increases. Set control as low as possible to avoid such interference.

1 Initial Time Control See Section 4-18. 2 Initial Amperage Control

See Section 4-18. 3 Final Slope Control See Section 4-19. 4 Final Amperage Control See Section 4-19. 5 Spot Time Control See Section 4-20.

(CE Nameplate)

OM-359 Page 50

Ref. ST-196 616 / Ref. ST-196 764

4-18. Initial Time Control And Initial Amperage Control

(CE Nameplate)

1 Initial Time Control Indicator light is on when Initial

Time control function is active. NOTE: Initial Sequence control

function i s inactive when Spot Time function is active.

Use control to select 0–15 seconds of start time.

2 Initial Amperage Control Indicator Light is on when Initial Se-

quence control function is active. NOTE: Initial Amperage control

function i s inactive when Spot Time function is active.

Use control to select a starting amperage (5–310 amps) that is different from the weld amperage. Note: Initial Amperage can be used with or without a remote control (Initial Amperage and Initial Time control settings will override a remote control device).

Application:

Initial Amperage can be used while GTAW welding to assist in preheating cold material prior to depositing filler material, or to ensure a soft start. Initial Amperage can also be used for SMAW to ensure a more consistent arc strike.

NOTE: Function is enabled, when LED is lit.

OM-359 Page 51

4-19. Final Slope Control And Final Amperage Control

(CE Nameplate)

1 Final Slope Control Indicator light is on when Final

Slope control function is active. Note: Final Slope control function

is inactive when Spot Time function is active.

Use control to reduce amperage over a set period of time (0–15 seconds) at the end of the weld cycle when NOT using a remote current control.

2 Final Amperage Control Indicator light is on when Final

Amperage control function is active.

Note: Final Amperage control function is inactive when Spot Time function is active (see Section 4-20).

Final amperage is the amperage to which weld amperage has sloped down to (0–100% of amperage set on Amperage Adjust control).

Application:

Final Sl o p e s h ould be used while GTAW welding materials that are crack sensitive, and/or the operator wants to eliminate the crater at the end of the weld.

Note: This applies if the operator is using an on/off only type control to start and stop the welding process.

Note: Do not use this function with a foot or finger amperage control.

NOTE: Function is enabled, when LED is lit.

4-20. Spot Time Control

OM-359 Page 52

1 Spot Time Control

(CE Nameplate)

Indicator light is on when Spot Time function is active. When Spot T i m e f u nction is active, Initial Time, Initial Amperage, Final Slope, and Final Amperage functions are inactive (see Section 4-17).

Used with the (GTAW) TIG Spot process, generally with a direct current electrode negative (DCEN) set-up.

Use control to select 0–15 seconds of spot time.

Use Amperage Adjust control (see Section 4-1 1) to set amperage.

Application:

TIG spot welding is used for joining thinner materials that are in close contact with the fusion method. A good example would be joining coil ends.

NOTE: Function is enabled, when LED is lit.

4-21. Timer/Cycle Counter

1 2 3

(CE Nameplate)

1 Amperage Control 2 Output Control (Contactor) To read timer/cycle counter, hold Amper-

age and Output (contactor) buttons while turning o n power.

3 Timer Display The hours and minutes are displayed on

the volt and amp meters for the first five seconds, and are read as 1, 234 hours and 56 minutes.

4 5 6

1 2 3

4 5 6

4 Cycle Display

The cycles are displayed on the volt and amp meters for the next five seconds, and are read as 123, 456 cycles.

OM-359 Page 53

4-22. Resetting Unit To Factory Default Settings (All Models)

1 Process Control 2 Amperage Control 3 Output Control 4 Start Control

OM-359 Page 54

5 Power Switch To reset all welding power source functions

to original factory settings, turn power off. Push and hold the Process, Amperage,

Output and Start controls and turn On power. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears meters).

CE Models

OM-359 Page 55

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

Adjust Spark

Gaps

5-2. Circuit Breaker CB1

14-Pin Cord

6 Months

During Heavy Service,

Repair Or

Replace

Cracked

Weld

Cables

Gas Hose

Blow Out Or Vacuum

Inside,

Clean Monthly

Clean An d

Tighten

Weld

Terminals

Replace Cracked

Parts

Torch Cable

1 Circuit Breaker CB1 If CB1 opens, high frequency and

output t o the 115 volts ac duplex receptacle stop. Press button to reset breaker.

OM-359 Page 56

Ref. ST-801 972

5-3. Adjusting Spark Gaps

Y Turn Off power before

adjusting spark gaps.

Open access door. 1 Tungsten End Of Point Replace point if tungsten end dis-

appears; do not clean or dress tungsten.

2 Spark Gap Normal spark gap is 0.012 in (0.305

mm). If adjustment is needed, proceed as

follows: 3 Adjustment Screws

Loosen screws. Place gauge of proper thickness in spark gap.

4 Pressure Point Apply slight pressure at point until

gauge is held firmly in gap. Tighten screws. Adjust other gap.

Reinstall access door.

Tools Needed:

0.012 in (0.305 mm)

5/32 in

Ref. ST-801 972 / Ref. S-0043

OM-359 Page 57

5-4. Voltmeter/Ammeter Help Displays

. All directions are in reference to the front

of the unit. All circuitry referred to is located inside the unit.

0 Help 0 Display Indicates a short in the thermal protection cir-

cuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent.

1 Help1 Display An SCR overcurrent condition has occurred.

Turn power off and back on to correct condition. If problem continues, contact a Factory Authorized Service Agent.

2 Help 2 Display Indicates a malfunction in the thermal

protection circuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent.

3 Help 3 Display Indicates the transformer of the unit has

overheated. The unit has shut down to allow

1 4

the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled.

4 Help 4 Display Indicates a malfunction in the thermal

protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.

5 Help 5 Display Indicates the rectifier assembly of the unit

has overheated. The unit has shut down to allow the fan to cool it (see Section 3-4). Operation will continue when the unit has cooled.

6 Help 6 Display Not used. 7 Help 7 Display Not used.

8 Help 8 Display

Not used. 9 Help 9 Display Indicates a short in the thermal protection cir-

cuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent.

10 Help 10 Display Indicates Remote Output control is acti-

vated. Release Remote Output control to clear help message.

11 Help 11 Display Indicates Output Selector switch is not in

correct position (see Section 4-2). 12 Help 12 Display Indicates a non-allowable set-up on the front

panel. 13 Help 13 Display AIC option, output enable signal broken

causing weld output to stop, but gas continues to flow.

HLP

--0

HLP

--5

HLP

--1

HLP

--6

HLP

--2

HLP

--7

HLP

--3

HLP

--8

HLP

--4

HLP

--9

-10

OM-359 Page 58

-11

-12

-13

5-5. Troubleshooting

Trouble Remedy

NOTE: The remedies listed below are recommendations only. If these remedies do not fix

the trouble with your unit, have a Factory Authorized Service Agent check unit.

There are no user serviceable parts inside unit.

Refer to Section 5-4 for any Help (HLP) message displayed on voltmeter/ammeter.

No weld output; unit completely inoperative.

No weld output; unit on. If using remote control, place Output control in Remote 14 position, and make sure remote control is

Unit provides only maximum or minimum weld output.

Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-6).

No control of weld output. If using remote control, place Output control in Remote 14 position, and make sure remote control is

No output from duplex receptacle RC2 and no high frequency.

Lack of high frequency; difficulty in starting GTA W arc.

Wandering arc – poor control of direction of arc.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to

Place line disconnect switch in On position (see Section 3-17). Check and replace line fuse(s), if necessary (see Section 3-17). Check for proper input power connections (see Section 3-17). Check for proper jumper link position (see Section 3-17).

connected to Remote 14 receptacle. If remote is not being used, place Output control in On position (see Section 4-1).

Check, repair, or replace remote control. Have Factory Authorized Service Agent check unit. Make sure Amperage control is in proper position (see Section 4-1). Have Factory Authorized Service Agent check unit.

Clean and tighten all weld connections. Check position of Output Selector control (see Section Figure 4-1). If using remote control, check position of Amperage Adjustment control (see Section 4-1).

connected to Remote 14 receptacle. If remote is not being used, place Output control in On position (see Section 4-1).

Make sure Amperage control is in proper position (see Section 4-1). Reset circuit breaker CB1 (see Section 5-2).

Reset circuit breaker CB1 (see Section 5-2). Select proper size tungsten. Check High Frequency Intensity control setting (see Figure 4-1). Be sure torch cable is not close to any grounded metal. Check cables and torch for cracked insulation or bad connections. Repair or replace. Check spark gaps (see Section 5-3). Reduce gas flow rate. Select proper size tungsten. Properly prepare tungsten. Shield weld zone from drafts. Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten. Check for water in torch, and repair torch if necessary.

protect against overheating.

OM-359 Page 59

SECTION 6 – ELECTRICAL DIAGRAM

OM-359 Page 60

202 484-A

Figure 6-1. Circuit Diagram For Non-CE Models

Figure 6-2. Circuit Diagram For CE Models

194 381-F

OM-359 Page 61

SECTION 7 – HIGH FREQUENCY

7-1. Welding Processes Requiring High Frequency

Work

TIG

7-2. Incorrect Installation

Weld Zone

11, 12

50 ft

(15 m)

1 High-Frequency Voltage TIG – helps arc jump air gap

between torch and workpiece and/ or stabilize the arc.

high_freq 12/96 – S-0693

10 9 8

4 5 6

Sources of Direct High-Frequency Radiation

1 High-Frequency Source (welding

power source with built-in HF or

separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table

OM-359 Page 62

Sources of Conduction of High Frequency

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

Sources of Reradiation of High Frequency

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

S-0694

7-3. Correct Installation

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

Nonmetal

Building

Weld Zone

50 ft

(15 m)

Ground workpiece if required by codes.

50 ft

(15 m)

1 High-Frequency Source (welding

power source with built-in HF or separate HF unit)

Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.

2 Center Point of Welding Zone Midpoint between high-frequency source

and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all

directions. 4 Weld Output Cables Keep cables short and close together.

Metal Building

5 Conduit Joint Bonding and Grounding Electrically join (bond) all conduit sections

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

6 Water Pipes and Fixtures Ground water pipes every 50 ft (15 m). 7 External Power or Telephone Lines Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines. 8 Grounding Rod Consult the National Electrical Code for

specifications.

Ref. S-0695 / Ref. S-0695

Metal Building Requirements

9 Metal Building Panel Bonding Methods Bolt or weld building panels together, install

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

10 Windows and Doorways Cover all windows and doorways with

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

11 Overhead Door Track Ground the track.

OM-359 Page 63

SECTION 8 – SELECTING AND PREPARING TUNGSTEN

ELECTRODE FOR DC OR AC WELDING

ac/dc_gtaw 2/2000

Y Whenever possible and practical, use DC weld output instead of AC weld output.

8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC – Argon – Electrode

2% Ceria (Orange Band), 1.5% Lan-

thanum (Gray Band), Or 2% Thorium

(Red Band) Alloy Tungstens

.010” Up to 25 * Up to 20 Up to 15 .020” 15-40 * 15-35 5-20 .040” 25-85 * 20-80 20-60 1/16” 50-160 10-20 50-150 60-120 3/32” 135-235 15-30 130-250 100-180

1/8” 250-400 25-40 225-360 160-250 5/32” 400-500 40-55 300-450 200-320 3/16” 500-750 55-80 400-500 290-390

1/4” 750-1000 80-125 600-800 340-525

Pure Tungsten

(Green Band)

.010” Up to 15 * Up to 15 Up to 10 .020” 5-20 * 5-20 10-20 .040” 15-80 * 10-60 20-30 1/16” 70-150 10-20 50-100 30-80 3/32” 125-225 15-30 100-160 60-130

1/8” 225-360 25-40 150-210 100-180 5/32” 360-450 40-55 200-275 160-240 3/16” 450-720 55-80 250-350 190-300

1/4” 720-950 80-125 325-450 250-400

Zirconium Alloyed Tungsten (Brown

Band)

.010” * * Up to 20 Up to 15 .020” * * 15-35 5-20 .040” * * 20-80 20-60 1/16” * * 50-150 60-120 3/32” * * 130-250 100-180

1/8” * * 225-360 160-250 5/32” * * 300-450 200-320 3/16” * * 400-550 290-390

1/4” * * 600-800 340-525

Negative/Straight Po-

larity

DC – Argon – Elec-

trode Positive/Rev-

erse Polarity

AC – Argon AC – Argon –

Balanced Wave

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended.

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. OM-359 Page 64

8-2. Preparing Tungsten Electrode For Welding

Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use

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

A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines

1 Tungsten Electrode

Electrode Diameter

2-1/2 Times

2 Tapered End Grind end of tungsten on fine grit,

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

Ideal Tungsten Preparation – Stable Arc

Wrong Tungsten Preparation – Wandering Arc

1 Stable Arc 2 Flat Diameter of this flat determines

amperage capacity. 3 Grinding Wheel Grinding wheel should be dedi-

cated to grinding tungsten only. 4 Straight Ground

1 Arc Wander 2 Point 3 Grinding Wheel Grinding wheel should be dedi-

cated to grinding tungsten only. 4 Radial Ground

B. Preparing Tungsten For Conventional AC Welding

1 – 1-1/2 Times

Electrode Diameter

1 Tungsten Electrode 2 Balled End

Y Understand and follow

safety symbols at start of Section 9-1 before preparing tungsten.

Ball end of tungsten by applying AC amperage recommended for a given electrode diameter (see Section 8-1). Let ball on end of the tungsten take its own shape.

OM-359 Page 65

SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW)

9-1. Positioning The Torch

Y Weld current can damage

electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P lace work clamp as close t o the weld as possible.

. For additional information, see

your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.

1 Workpiece Make sure workpiece is clean

before welding. 2 Work Clamp Place as close to the weld as

possible. 3 Torch 4 Filler Rod (If Applicable) 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten

according to Sections 8-1 and 8-2.

Guidelines:

The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in diameter, gas cup should be a minimum of 3/16 in diameter.

Tungsten extension is the distance the tungsten extends out gas cup of torch.

The tungsten extension should be no greater than the inside diameter of the gas cup.

Arc length is the distance from the tungsten to the workpiece.

10–25°

90°

10–15°

1/16 in

OM-359 Page 66

3/16 in

Bottom View Of Gas Cup

Ref. ST-161 892

9-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool Tilt torch Move torch to front

Tungsten With Filler Rod

Welding direction

Form pool Tilt torch Add filler metal

Remove rod

75°

of pool. Repeat process.

75°

15°

Move torch to front

of pool. Repeat process.

ST-162 002-B

OM-359 Page 67

9-3. Positioning Torch Tungsten For Various Weld Joints

90°

Butt Weld And Stringer Bead

20°

“T” Joint

70°

75°

Lap Joint

Corner Joint

10°

15°

20-40°

75°

15°

30°

90°

75°

OM-359 Page 68

15°

ST-162 003 / S-0792

SECTION 10 – STICK WELDING (SMAW) GUIDELINES

10-1. Stick Welding Procedure

Y Weld current starts when

electrode touches workpiece.

Y Weld current can damage

electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P lace work clamp as close t o the weld as possible.

1 Workpiece Make sure workpiece is clean be-

fore welding. 2 Work Clamp 3 Electrode A small diameter electrode requires

less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 10-2).

4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the

electrode t o the workpiece. A short arc with correct amperage will give a sharp, crackling sound.

7 Slag Use a chipping hammer and wire

brush to remove slag. Remove slag and check weld bead before making another weld pass.

Tools Needed:

stick 12/96 – ST-151 593

OM-359 Page 69

10-2. Electrode and Amperage Selection Chart

RANGE

AMPERAGE

ELECTRODE

6010

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8

5/32 3/16 7/32

1/4

1/16 5/64 3/32

1/8

5/32 3/16 7/32

1/4

3/32

1/8

5/32 3/16 7/32

1/4

3/32

1/8

5/32 3/16 7/32

1/4

3/32

1/8

5/32 3/16 7/32

1/4

3/32

1/8

5/32 3/16 3/32

1/8

5/32

100

150

200

250

300

350

400

450

DC*

ELECTRODE

6010

6011

EP,EN

6013

EP,EN

7014

7018

EP,EN

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

POSITION

ALL ALL ALL

ALL ALL

FLAT

HORIZ

FILLET

ALL ALL

PENETRATION

DEEP DEEP

LOW MED

LOW

LOW LOW

LOW

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON STAINLESS

Ref. S-087 985-A

10-3. Striking an Arc – Scratch Start Technique

10-4. Striking an Arc – Tapping Technique

1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece

like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.

S-0049

1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to

workpiece; then lift slightly to start

arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.

S-0050

OM-359 Page 70

10-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

End View of Work Angle Side View of Electrode Angle

10-6. Poor Weld Bead Characteristics

FILLET WELDS

10°-30°

S-0060

1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration

10-7. Good Weld Bead Characteristics

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being w elded.

5234

4 No Overlap 5 Good Penetration into Base

Metal

OM-359 Page 71

S-0053-A

S-0052-B

10-8. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.

Angle Too Small

Too Short

Slow

Correct Angle

10° - 30°

Drag

ELECTRODE ANGLE

Normal Too Long

ARC LENGTH

Normal Fast

TRAVEL SPEED

Angle Too Large

Spatter

S-0061

10-9. Electrode Movement During Welding

NOTE

Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.

1 Stringer Bead – Steady

Movement Along Seam

2 Weave Bead – Side to Side

Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode.

S-0054-A

OM-359 Page 72

10-10.Butt Joints

10-11.Lap Joint

Single-Layer Fillet Weld

1 Tack Welds

1/16 in

(1.6 mm)

30° Or Less

30°

30° Or Less

Multi-Layer Fillet Weld

Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld.

2 Square Groove Weld Good for materials up to 3/16 in (5

mm) thick. 3 Single V-Groove W eld Good for materials 3/16 – 3/4 in

(5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.

Create 3 0 degree angle of bevel on materials in V -groove welding.

4 Double V-Groove W eld Good for materials thicker than 3/16

in (5 mm).

S-0662

1 Electrode 2 Single-Layer Fillet Weld Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavi-

er fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength.

S-0063 / S-0064

10-12.Tee Joint

45°

Or Less

1 Electrode 2 Fillet Weld Keep arc short and move at definite

rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface.

For maximum strength weld both

sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavi-

er fillet is needed. Use any of the weaving patterns shown in Section 10-9. Remove slag before making another weld pass.

S-0060 / S-0058-A / S-0061

OM-359 Page 73

10-13.Weld Test

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2 1

10-14.Troubleshooting – Porosity

Porosity – small cavities or holes resulting from gas pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

1 Vise 2 Weld Joint 3 Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

S-0057-B

Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

10-15.Troubleshooting – Excessive Spatter

Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage.

OM-359 Page 74

10-16.Troubleshooting – Incomplete Fusion

Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique. Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

10-17.Troubleshooting – Lack Of Penetration

Lack Of Penetration – shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

10-18.Troubleshooting – Excessive Penetration

Excessive Penetration – weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Good Penetration

Increase and/or maintain steady travel speed.

OM-359 Page 75

10-19.Troubleshooting – Burn-Through

Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

10-20.Troubleshooting – Waviness Of Bead

Waviness O f Bead – weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

10-21.Troubleshooting – Distortion

Distortion – contraction of weld met- al during welding that forces base metal t o move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds.

OM-359 Page 76

Notes

OM-359 Page 77

SECTION 11 – PARTS LIST

1516

. Hardware is common and

not available unless listed.

6–Fig. 1 1-2

18 19

28-Fig. 11-4

OM-359 Page 78

Figure 11-1. Main Assembly

34–Fig. 11-3

802 609-B

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

1 PC1 203 899 Circuit Card Assy, Interface (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186 914 Display, LED Numeric 7 Segment 3 Digit (LED’s 18 – 23) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 PC1 203 899 Circuit Card Assy, Interface (consisting of) (CE Models Only) 1. . . . . . . . . . . . . . . . . . . . . . .

186 914 Display, LED Numeric 7 Segment 3 Digit (LED’s 18 – 23) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13, 15 131 054 Connector W/Sockets 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 130 203 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG14 115 092 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 115 093 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG17 131 052 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG16 115 091 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 195 778 Actuator Push Button Assy 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 190 512 Stand–off, No 6–32 X .6406 Lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC2 ♦190 734 Circuit Card, Pulser 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 ♦190 738 Circuit Card, Sequencer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 196 762 Hf Control Box Assy, ( Figure 11-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 204 289 Panel, Side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 590 Label, Miller 12.563 X 5.376 Horizontal Syncrowav 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 204 312 Top, Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 R3 201 133 Resistor, WW Fxd 400 W 35 Ohm W/Mtg Bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 +204 291 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127 363 Label, Warning Electric Shock Can Kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168 384 Label, Warning Electric Shock And Incorrect Input P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 168 343 Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 184 057 Door, Primary Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 491 Spacer, Hinge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 605 227 Nut, 750–14 Knurled1.68dia .41h Nyl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 GS1 133 873 Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 969 Plug, Protective No 6 Plastic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 010 146 Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 176 272 Conn, Clamp Cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 202 485 Baffle, Rear Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186 162 Relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 184 058 Fan, Plenum 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 1T 199 312 Block, Terminal Fast–on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 150 783 Blade, Fan 9.000 5wg 39deg .312 Bore Cw Plstc 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 FM1, FM2 188 706 Motor, Fan 230v 50/60hz 1550 Rpm .312 Dia Shaft 2. . . . . . . . . . . . . . . . . . . . . . . . . .

22 187 807 Bracket, Mtg Motor Fan 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 192 864 Support, Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 026 627 Gasket, Lifting Eye Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 T1, Z1 194 379 Xfmr/Stabilizer Assy, 200/230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 T1, Z1 196 715 Xfmr/Stabilizer Assy, 230/460/575 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 T1, Z1 196 711 Xfmr/Stabilizer Assy, 220/400/440/520 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TH1 201 443 Thermistor, NTC 10k ohm @ 25 deg C 27.5 in lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 202 119 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 202 116 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 202 117 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 202 118 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 200 647 Bracket, Support Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 192 862 Bracket, Mtg Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 SR1 196 485 Rectifier Assy, (Figure 11-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 603 Tubing, Gl Acryl 1.000–1.036 Idxspool Nat Fa1 0.875. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 184 052 Baffle, Cap Power Factor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 C5, C6 111 634 Capacitor Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 TE1 034 587 Term Assy, Pri 1ph 3v (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083 426 Terminal Board, pri 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 618 Link, jumper term bd pri 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 835 Nut, brs hex 10-32reg 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 836 Nut, brs hex .250-20 jam hvy 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 888 Stud, pri board brs .250-20 x 1.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 887 Stud, pri board brs 10-32 x 1.375 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 913 Washer, flat brs .187 ID 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 915 Washer, flat brs .250 ID x .625 OD x .031thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 207 Washer, lock .255 ID x .489 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175 479 Link, jumper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-359 Page 79

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-1. Main Assembly (continued)

190 161 Lug, Univ W/Screw 1/O–14 Wire .266std 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 +196 584 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

155 436 Label, Ground/Protectiv 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 189 224 End Cap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 197 026 HF Panel Assy, Lower (Figure 11-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 S1 128 757 Switch, Tgl Dpst 60a 600vac Scr Term Wide Tgl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 R5 198 547 Rheostat, Ww 25. W 1.5 Ohm Fric Term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 S5 201 121 Switch Assy, Polarity With Leads And Hardware (Dx) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 204 305 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143 397 Blank, Snap–in Nyl .312 Mtg Hole Black 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117 860 Blank, Snap–in Nyl .187 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 983 Blank, Snap–in Nyl .500 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 097 922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174 041 Label, Indicator Intensity Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 +196 492 Door, Access Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 327 Label, Warning General Precautionary Static&wire Fe 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127 363 Label, Warning Electric Shock Can Kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 175 952 Plastic, Handle Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 194 388 Nameplate, Miller Syncrowave 250DX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 196 766 Nameplate, Miller Syncrowave 250DX (Wordless) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 184 066 Door Spark Gap Access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 196 616 Plate, Indicator Syncrowave 250DX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 196 764 Plate, Indicator Syncrowave 250DX (Wordless) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 183 332 Knob, Pointer .570 Dia X .125 Id W/Spring Clip 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 174 991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip–.21 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 204 416 Drawer, Mat 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 204 313 Drawer, Tray 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 204 307 Slide, Drawer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 204 314 Drawer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 204 389 HOLDER, Torch/Cable (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 200 920 Door, Torch/Cable Holder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 200 922 Housing, Torch/Cable Holder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 494 907 SCREW, k50 x 20 pan hd – trx pld pt thread forming 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦ OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-359 Page 80

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

196 762

Figure 11-2. HF Control Box Assembly (Figure 11-1 Item 6)

1 G1 199 854 Spark Gap Assy, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 855 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 856 Holder, Points 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 455 Points, Spark Gap 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 184 068 Bracket, Spark Gap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C3 201 197 Capacitor, Polyp Met Film .002uf 4400vacpnlmtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R8 188 067 Resistor, ww fxd 100 w 200 ohm w/clips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 C11, C19 195 552 Capacitor, Polyp Met Film 20. Uf 250 Vac 10% 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 R2 189 132 Resistor Assy, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 R1 186 468 Resistor, Ww Fxd 100 W 50 Ohm W/Clips 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 493 Bushing, Snap–in Nyl .625 Id X .875 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 196 576 Hf, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 T3 074 398 Xfmr, High Voltage 115v Pri 3600v Sec 30 Ma 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Hardware is common and

not available unless listed.

Figure 11-2. HF Control Box Assembly

802 756

OM-359 Page 81

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

197 026

Figure 11-3. HF Panel Assembly, Lower (Figure 11-1 Item 34)

1 197 022 Panel, Lower Hf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 193 415 Connector, Faston 1/4 Ring W/75deg Bend 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 RC2/CB1/C12 201 153 Receptacle, W/Leads And Circuit Breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156 734 Nut, 010–32 .31hex .13h Stl Pld Sem Cone Wshr.38d 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 RC1 201 127 Harness, Assy 14 Pin Recpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 143 976 Connector W/Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CM1 197 220 Module, Filter .1mf 500vdc 8 Ckt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 089 120 Clamp, Hose .375 – .450 Clp Dia Slfttng Green 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 155 527 Hose, Nprn Brd No 1 X .250 Id X 28.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 120 854 Ftg, Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 C13, C14 196 499 Capacitor Assy, 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 157 317 Holder, Hf Coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T4 199 487 Coil, Hf Coupling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203 474 Service Kit, DX Coupling Coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 157 318 Holder, Hf Coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 097 421 Terminal, Pwr Output Red 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Hardware is common and

not available unless listed.

2 3

802 757

Figure 11-3. HF Panel Assembly, Lower

OM-359 Page 82

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

196 485

Figure 11-4. HF Rectifier Assembly (Figure 11-1 Item 28)

1 Mod 1, 2 196 760 Thyristor, SCR Module 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 196 191 Heat Sink, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 HD1 191 941 Transducer, Current Hall 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TH2 188 431 Thermister, NTC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 196 171 Insulator, Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 C7, 8, 9, 10 190 460 Capacitor Assy 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Hardware is common and

not available unless listed.

Figure 11-4. Rectifier Assembly

Ref. 802 609-A

OM-359 Page 83

Warranty Questions?

Call 1-877-HOBART1 for your local Hobart distributor.

Service

Y ou 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 or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart Welding Products., Troy, Ohio, warrants to its original ret a i l p urchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSL Y IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart will provide instructions on the warranty claim procedures to be followed.

Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or e i ghteen 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

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * Intellitig * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer .)

3. 1 Year — Parts and Labor

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Hobart Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches * Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & Spoolmate 250 * Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

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

2. Items furnished by Hobart, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Hobart, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobart’s option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation bas e d u p o n actual use) upon return of the goods at customer’s risk and expense. Hobart’s option of repair or replacement will be F .O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

hobart standard 7/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Distributor, retail or service location:

Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

File a claim for loss or damage during shipment.

Hobart Welding Products

An Ill inoi s Tool Works Company 600 West Main Street Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1

PRINTED IN USA  2000 Hobart Welding Products. 1/00

Hobart CYBERTIG 250 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual