Miller CST 280 VRD WITH METER Owners manual

OM-258035G 2016−04

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Arc Welding Power Source

CST 280 And CST 280 VRD

With Meter

Visit our website at

www.MillerWelds.com

File: Stick (SMAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

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

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Symboles utilisés 5.....................................................................

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

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Additional Safety Symbols And Definitions 9................................................

3-2. Miscellaneous Symbols And Definitions 9..................................................

SECTION 4 − SPECIFICATIONS 10..............................................................

4-1. Serial Number And Rating Label Location 10................................................

4-2. Unit Specifications 10....................................................................

4-3. Environmental Specifications 11...........................................................

4-4. Duty Cycle And Overheating 11...........................................................

4-5. Stick (SMAW) Volt-Ampere Curves CST 280 Model 12........................................

4-6. TIG (GTAW) Volt-Ampere Curve CST 280 Model 12..........................................

4-7. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model 13...................................

4-8. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model 13......................................

SECTION 5 − INSTALLATION 14................................................................

5-1. Selecting a Location 14..................................................................

5-2. Weld Output Terminals And Selecting Cable Sizes* 15........................................

5-3. Weld Output Terminals 15................................................................

5-4. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections 16........................

5-5. Stick DCEP (Direct Current Electrode Positive) Connections 16................................

5-6. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage 17..............................

5-7. Selecting 400 - 575 Volts AC Three Phase Input Voltage 18....................................

5-8. Electrical Service Guide 19...............................................................

5-9. Connecting 1-Phase Input Power 20.......................................................

5-10. Connecting 3-Phase Input Power 22.......................................................

SECTION 6 − OPERATION 24...................................................................

6-1. Controls 24............................................................................

6-2. Process Select Control 25................................................................

6-3. Stick Start Procedure − Scratch Start Technique 25...........................................

6-4. Lift-Arc™ Start Procedure 26..............................................................

6-5. Remote 14 Receptacle Information 26......................................................

6-6. Fan-On-Demand 26.....................................................................

6-7. Rack Mounting 26.......................................................................

TABLE OF CONTENTS

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 27.......................................

7-1. Routine Maintenance 27.................................................................

7-2. Blowing Out Inside Of Unit 27.............................................................

7-3. Troubleshooting 28......................................................................

SECTION 8 − ELECTRICAL DIAGRAMS 32.......................................................

SECTION 9 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES 34........................................

9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 34......

9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines 34...................................................

SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) 35.......................................

SECTION 11 − PARTS LIST 38..................................................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

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 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

 Do not touch live electrical parts.

 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats

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

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

there is a danger of falling.

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

unit.

 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

 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).

 Properly install, ground, and operate this equipment according to

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

 Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

 Always verify the supply ground − check and be sure that input

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

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

 Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

 Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or repaired cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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

or another electrode from a different machine.

 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

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

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal. Disconnect cable for process not in
use.

 Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

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

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

HOT PARTS can burn.

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

equipment.

 To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-258035 Page 1

FUMES AND GASES can be hazardous.

)

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

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Safety Data Sheets (SDSs) and the

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

 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 the oxygen level causing injury or death. Be sure the breath­ing air is safe.

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

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

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

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

ARC RAYS can burn eyes and skin.

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

 Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

 Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

 Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

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

from your person before doing any welding.

 After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

 Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

 Read and understand the Safety Data Sheets (SDSs) and the

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

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

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

 Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

 Wear approved ear protection if noise lev-

el is high.

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.

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

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

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

 Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

 Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

 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, sparks, and fire
hazards.

 Do not use welder to thaw frozen pipes.

OM-258035 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

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

 Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

 Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

 Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

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

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

 Do not install unit near flammables.

 Do not overload building wiring − be sure power supply system is

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

FALLING EQUIPMENT can injure.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

 Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

 Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

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

starting to weld again.

 Do not block or filter airflow to unit.

MOVING PARTS can injure.

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

closed and securely in place.

 Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

 Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

 Use only genuine replacement parts from the manufacturer.
 Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

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

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

 Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

 Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

BATTERY EXPLOSION can injure.

 Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

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

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

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

ly correct any interference problem resulting from the installa­tion.

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

equipment at once.

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

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

ARC WELDING can cause interference.

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

 If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

OM-258035 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment 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.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

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

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-258035 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

fre_som_2015−09

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.

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

Les symboles représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec­tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimen­tation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

 Ne pas toucher aux pièces électriques sous tension.
 Porter des gants isolants et des vêtements de protection secs et

sans trous.

 S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

 Ne pas se servir de source électrique à courant électrique dans les

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

 Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère

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

 D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

 Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

 Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, 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).

 Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.

 Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer 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.

 En effectuant les raccordements d’entrée, fixer d’abord le conduc-

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

 Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

 Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî­ner la mort.

 L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
 Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

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

avec un câble distinct.

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

la terre ou une électrode provenant d’une autre machine.

 Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

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

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

 Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
 S’assurer que tous les panneaux et couvercles sont correctement

en place.

 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 la soudure.

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

contact avec tout objet métallique.

 Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

 Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

 Arrêter les convertisseurs, débrancher le courant électrique et

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

OM-258035 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

provoquer des brûlures.

 Ne pas toucher à mains nues les parties chaudes.
 Prévoir une période de refroidissement avant

de travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.

 Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

 Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.

 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.

 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.

 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 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 RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génèr

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
peau. Des étincelles sont projetées pendant le soudage.

 Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux 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).

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

des rayons visibles et invisibles intenses (ultraviolets

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

être projetées de l’arc de soudure. La projection d’étincelles, 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 sur-

OM-258035 Page 6

provoquer leur éclatement. Des étincelles peuvent

chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.

 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.

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

sur des substances inflammables.

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

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

 Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

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

peut déclencher un incendie de l’autre côté.

 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 et AWS A6.0
(voir les Normes de Sécurité).

 Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

 Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

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

lées.

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

électrode ou couper le fil à la pointe de contact.

 Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

 Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

 Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

 Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

 Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

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

 Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

 Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

 Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

LE BRUIT peut endommager l’ouïe.

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

 Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est

les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.

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

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support station-

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

endommagée, elle peut exploser. Du fait que

 Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

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

 Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

 Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

 Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

 Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

 Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de pro-

duits inflammables.

 Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

 Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

 Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

 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.

 Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

 Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

 Porter un écran facial pour protéger le visage et

les yeux.

 Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé­cuter dans un endroit sûr lorsque l’on porte l’équipement ho­mologué de protection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

 Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

 Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

 S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

 Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.

 Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

 Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal­lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

 Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

OM-258035 Page 7

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

 Le rayonnement haute fréquence (H.F.) peut

pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

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

qualifié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’appareil.
 Effectuer régulièrement le contrôle et l’entretien de l’installation.
 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 un blindage pour réduire les
interférences éventuelles.

provoquer des interférences avec les équi-

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

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

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

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

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

2-4. Proposition californienne 65 Avertissements

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

 L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

patible électromagnétiquement.

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

électronique sensible.

conformément à ce mode d’emploi.

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles 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.

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-258035 Page 8

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

 Some symbols are found only on CE products.

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

Always connect green wire to supply grounding terminal, never to a
line terminal.
Connect black, white, and red wires (L1, L2, L3) to line terminals.
Read manual.

3-2. Miscellaneous Symbols And Definitions

 Some symbols are found only on CE products.

Safe1 2012−05

Safe115 2013−06

Single Phase Three Phase

Off On Output Temperature

Hz

Hertz Percent

OM-258035 Page 9

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Unit Specifications

 Do not use information in unit specifications table to determine electrical service requirements. See Section 5-8, 5-9, and 5-10 for information on

connecting input power.

A. 208-230/400-460 Volts Model*

Welding

Mode

Stick

(SMAW)

*Unit can be ordered with Dinse or Tweco weld output receptacles.

Input

Power

3-Phase

1-Phase

Rated

Output

280 A @

31.2 VDC,
35 % Duty

Cycle

200 A @
28 VDC,

100 %

Duty Cycle

200 A @
28 VDC,

50 % Duty

Cycle

150 A @
26 VDC,

100 %

Duty Cycle

Welding

Amperage

Range

5-280 A

5-200 A

Maximum

Open-Circuit

Voltage

67 VDC

B. 220-230/460-575 Volts Model*

Welding

Mode

Stick

(SMAW)

*Unit comes with Tweco weld output receptacles.

Input

Power

3-Phase

1-Phase

Rated

Output

280 A @

31.2 VDC,
35 % Duty

Cycle

200 A @
28 VDC,

100 %

Duty Cycle

200 A @
28 VDC,

50 % Duty

Cycle

150 A @
26 VDC,

100 %

Duty Cycle

Welding

Amperage

Range

5-280 A

5-200 A

Maximum

Open-Circuit

Voltage

77 VDC

Amperes Input At Rated

Load Output, 50/60 Hz

208 230 400 460

36.0 34.0 19.8 17.5 14.0 10.2

23.5 22.8 13.5 12.7 10.2 6.9

43.9 43.0 n/a n/a 9.9 6.5

35.0 32.9 n/a n/a 7.6 4.8

Amperes Input At Rated

Load Output, 50/60 Hz

220 230 460 575

35.0 34.2 17.8 14.7 14.6 10.2

23.3 22.5 11.7 9.7 9.6 6.4

43.9 43.0 n/a n/a 10.1 6.6

32.7 32.0 n/a n/a 7.3 4.6

KVA KW Dimensions

KVA KW Dimensions

H: 13-1/2 in.

(343 mm)

W: 7-1/2 in.

(191 mm)

D: 18 in. (457

mm)

H: 13-1/2 in.

(343 mm)

W: 7-1/2 in.

(191 mm)

D: 18 in.

(457 mm)

Net

Weight

41 lb

(18.6 kg)

Net

Weight

41 lb

(18.6 kg)

OM-258035 Page 10

C. 208-230/400-460 Volts VRD Model*

Welding

Mode

Stick

(SMAW)

*Unit comes with Dinse weld output receptacles.

Input

Power

3-Phase

1-Phase

Rated

Output

280 A @

31.2 VDC,
35 % Duty

Cycle

200 A @
28 VDC,

100 %

Duty Cycle

200 A @
28 VDC,

50 % Duty

Cycle

150 A @
26 VDC,

100 %

Duty Cycle

Welding

Amperage

Range

5-280 A

5-200 A

Maximum

Open-Circuit

Voltage

30 VDC

Amperes Input At Rated

Load Output, 50/60 Hz

208 230 400 460

36.0 34.0 19.8 17.5 14.0 10.2

23.5 22.8 13.5 12.7 10.2 6.9

43.9 43.0 n/a n/a 9.9 6.5

35.0 32.9 n/a n/a 7.6 4.8

KVA KW Dimensions

H: 13-1/2 in.

(343 mm)

W: 7-1/2 in.

(191 mm)

D: 18 in. (457

mm)

4-3. Environmental Specifications

IP Rating

IP23

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.

Net

Weight

41 lb

(18.6 kg)

IP23 2014−06

4-4. Duty Cycle And Overheating

300

280
250

200

150

100

WELDING AMPERES

50

0

10 20 30 40 50 60 70 80 90 100

% DUTY CYCLE

200 A @ 50% Duty Cycle For Single Phase Operation

5 Minutes Welding 5 Minutes Resting

Overheating

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

3 PHASE
OPERATION

SINGLE PHASE
OPERATION

280 A @ 35% Duty Cycle For 3 Phase Operation

3-1/2 Minutes Welding 6-1/2 Minutes Resting

0

If unit overheats, output stops, and
cooling fan runs. Wait fifteen
minutes for unit to cool. Reduce
amperage or duty cycle before
welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

221 587-A

A or V

Minutes

15

OR

Reduce Duty Cycle

OM-258035 Page 11

4-5. Stick (SMAW) Volt-Ampere Curves CST 280 Model

xx10 Stick VA Curves

xx18 Stick VA Curve

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

4-6. TIG (GTAW) Volt-Ampere Curve CST 280 Model

TIG VA Curve

OM-258035 Page 12

Ref. 221 588-A

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

Ref. 221 588-A

4-7. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model

xx10 Stick VA Curves

xx18 Stick VA Curve

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

4-8. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model

TIG VA Curve

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

OM-258035 Page 13

SECTION 5 − INSTALLATION

5-1. Selecting a Location

Movement

! Do not move or operate unit

1

where it could tip.

Location And Airflow

18 in.

(460 mm)

Notes

2

18 in.

(460 mm)

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

1 Lifting Handle
Use handle to lift unit.
2 Line Disconnect Device
Locate unit near correct input

power supply.

loc_small 2015-04

OM-258035 Page 14

5-2. Weld Output Terminals And Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less

10 − 60%

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)

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

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

Duty

Cycle

AWG (mm2)

60 − 100%

Duty Cycle

AWG (mm2)

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 − 100% Duty Cycle

AWG (mm2)

350 ft

(105 m)

400 ft

(120 m)

Ref. S-0007-L 2015−02

5-3. Weld Output Terminals

1

! Turn off power before connecting

to weld output terminals.

! Do not use worn, damaged, un-

dersized, or repaired cables.

1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

 For welding output terminal connec-

tions see Sections 5-4 thru 5-5 for
typical connection processes.

2

output term1 2015−02

OM-258035 Page 15

5-4. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections

1 Positive (+) Weld Output

Terminal

Connect work lead to positive weld
output terminal.

2 Negative (−) Weld Output

5

6

3

1

2

4

Terminal

Connect TIG torch to negative weld
output terminal.

3 Gas Cylinder
4 Cylinder Valve
Open valve slightly so gas flow

blows dirt from valve. Close valve.
5 Regulator/Flowmeter
6 Flow Adjust
Typical flow rate is 15 cubic feet per

hour (7.1 liters per minute).
Connect torch gas hose to

regulator/flowmeter.
7 Gas Valve
Valve controls gas preflow and

postflow. Open valve on torch just
before welding.

Tools Needed:

7

5-5. Stick DCEP (Direct Current Electrode Positive) Connections

2

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

258 647-A

1 Negative (−) Weld Output

Terminal

Connect work lead to negative weld
output terminal.

2 Positive (+) Weld Output

Terminal

Connect electrode holder to
positive weld output terminal.

OM-258035 Page 16

1

258 648-A

5-6. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage

! Turn Off welding power

208-230/400-460 Volts Model

208−230

VAC

400−460

VAC

1

2

Check input voltage available at
site.

1 Switch Cover
2 Voltage Selection Switch
The input voltage that the power

source is linked for is labeled next to
the switch.

Check voltage selected on unit.
Changing selection is only
necessary if selected value does
not match available input voltage.

! Do not switch under load.

To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The main power circuit board

220-230/460-575 Volts Model

1

 The switch has an off position

Be sure that switch is turned

220−230

VAC

460−575

VAC

completely to its detent position.

source, and disconnect
input power before
proceeding.

is protected at power up from
voltage surges or over
voltage conditions that can
occur if plugged into improper
line voltages (such as when
linked for 220-230 or 208-230
and powered with 460-575 or
400-460). If this situation
does happen, turn off welding
power source, open rear
switch cover, and turn Voltage
Selection switch to the
correct input voltage. Wait 10
minutes before turning
welding power source back
on again to allow the
protection to reset.

at 905 straight up.

Tools Needed:

2

Ref. 803 945-A / Ref. 803 946-A

OM-258035 Page 17

5-7. Selecting 400 - 575 Volts AC Three Phase Input Voltage

208-230/400-460 Volts Model

208−230

VAC

400−460

VAC

1

2

! Turn Off welding power

source, and disconnect
input power before
proceeding.

Check input voltage available at
site.

1 Switch Cover
2 Voltage Selection Switch
The input voltage that the power

source is linked for is labeled next to
the switch.

Check voltage selected on unit.
Changing selection is only
necessary if selected value does
not match available input voltage.

! Do not switch under load.

To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position

at 905 straight up.

Be sure that switch is turned
completely to its detent position.

220-230/460-575 Volts Model

220−230

VAC

460−575

VAC

1

2

Tools Needed:

OM-258035 Page 18

Ref. 803 945-A / Ref. 803 946-A

5-8. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.

Elec Serv 2014−01

50/60 Hz Single-

Phase, 50% Duty

Cycle

Input Voltage (V) 208 220 230 208 220 230 400 460 575

Input Amperes (A) At Rated Output 43.9 43.9 43.0 36.0 35.0 34.2 19.8 17.8 14.7

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay Fuses

Normal Operating Fuses 3 70 70 70 60 60 50 30 25 20

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

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

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

4

4

2

50 50 50 45 45 45 25 20 15

8 8 8 10 10 10 14 14 14

117

129
(39)

141
(43)

(36)

8 8 8 10 10 10 14 14 14

50/60 Hz Three-Phase,

35% Duty Cycle

101

113

(31)

(34)

123
(38)

149
(45)

196

(60)

306
(93)

Notes

OM-258035 Page 19

5-9. Connecting 1-Phase Input Power

1

8

L1

3

6

=GND/PE Earth Ground

10

7

9

1

L2

3

1

2

6

5

4

Tools Needed:

OM-258035 Page 20

Input1 2012−05 − Ref. 803 766-C / 258 649-A

5-9. Connecting 1-Phase Input Power (Continued)

! Installation must meet all National

and Local Codes − have only qualified
persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input con­ductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.

! Always connect green or green/yel-

low conductor to supply grounding
terminal first, and never to a line ter­minal.

Notes

See rating label on unit and check input
voltage available at site.

1 Black And White Input Conductor (L1

And L2)
2 Red Input Conductor
3 Green Or Green/Yellow Grounding

Conductor
4 Insulation Sleeving
5 Electrical Tape
Insulate and isolate red conductor as shown.
6 Input Power Cord.
7 Disconnect Device (switch shown in

the OFF position)

8 Disconnect Device Grounding Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor to disconnect device grounding
terminal first.

Connect input conductors L1 and L2 to
disconnect device line terminals.

10 Over-Current Protection
Select type and size of over-current

protection using Section 5-8 (fused
disconnect switch shown).

Close and secure door on disconnect device.
Follow established lockout/tagout proced­ures to put unit in service.

Input1 2012−05

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-258035 Page 21

5-10. Connecting 3-Phase Input Power

4

3

= GND/PE Earth Ground

7

2

L1

3

6

1

L2

L3

5

Tools Needed:

OM-258035 Page 22

Input2 2012−05 − Ref. 803 766-C / 258 649-A

5-10. Connecting 3-Phase Input Power (Continued)

! Installation must meet all National

and Local Codes − have only qualified
persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input
conductors from unit. Follow
established procedures regarding
the installation and removal of
lockout/tagout devices.

! Always connect green or

green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.

Notes

See rating label on unit and check input volt­age available at site.

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

the OFF position)

3 Green Or Green/Yellow Grounding

Conductor
4 Disconnect Device Grounding Terminal
5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals

Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.

Connect input conductors L1, L2, and L3 to
disconnect device line terminals.

7 Over-Current Protection
Select type and size of over-current protec-

tion using Section 5-8 (fused disconnect
switch shown).

Close and secure door on disconnect device.
Follow established lockout/tagout proced­ures to put unit in service.

Input2 2012−05

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-258035 Page 23

6-1. Controls

1

SECTION 6 − OPERATION

32 4

7

 Green on nameplate indicates a TIG

function and Gray indicates a Stick
function.

1 Power Switch
Use switch to turn unit and indicator light

On/Off.
2 High Temperature Shutdown Light
When unit is first energized this indicator

light illuminates for approximately 1 second
to provide visual confirmation that the light
is functioning properly (see Section 4-4).

3 Output Indicator Light
When unit is first energized this indicator

light flashes several times and then
illuminates continuously. When unit is shut
down, the indicator light flashes several
times and the cooling fan will run briefly, then
both will turn off completely.

4 Ammeter Display
The display shows amperage setting in both

stick and TIG processes. Actual amperage
is displayed while welding and indicated

5

with the trailing decimal point illuminated.
Measured amperage just prior to the end of
a welding operation will appear on the
display for 10 seconds after welding ends.

5 Process Control
See Section 6-2.
6 AMPS (Amperage Control)
Rotate knob clockwise to increase

amperage (5−280 amps).
7 Remote 14 Receptacle

6

OM-258035 Page 24

Ref. 257 571-A / 258 649-A

6-2. Process Select Control

RECOMMENDED PROCESS

SELECTIONS VS ELECTRODE TYPE

ELECTRODE

TYPE

EXXX1
EXXX2

EXXX3
EXXX4
EXXX5
EXXX6
EXXX7
EXXX8

STAINLESS

SUGGESTED PROCESS

SETTING

EXX10
EXX10

EXX18
EXX18
EXX18
EXX18
EXX18
EXX18
EXX18

1 Process Select Control
Rotate knob to select desired

process.
Lift-Arc TIG - Normal open-cir-

cuit voltage is not present between
the electrode and workpiece. A sol­id-state contactor does not ener-

1

gize until after the electrode
touches the workpiece, preventing
overheating, sticking, or contamin­ating the electrode (see Section
6-4). Make connections according
to Section 5-4.

Stick EXX18 Soft - This setting
provides a lower dig/arc force
setting for smooth weld perfor­mance. A stable weld puddle with
little arc “snap” gives excellent weld
bead appearance with minimal
spatter. Make connections
according to Section 5-5.

Stick EXX18 Stiff - This setting
provides a higher dig/arc force that
gives a slightly more fluid weld
puddle, more arc “snap”, and
reduces the potential for electrode
sticking at shorter arc lengths.
Make connections according to
Section 5-5.

Stick EXX10 Soft - This setting
provides lower dig/arc force for
open root vertical up joints or joints
that do not require additional
current for fit up inconsistencies.
Make connections according to
Section 5-5.

Stick EXX10 Stiff - This setting
provides a higher dig/arc force for
open root vertical down joints
where additional current is needed
to compensate for tight joint fit up
without the need to increase overall
welding current. Make connections
according to Section 5-5.

6-3. Stick Start Procedure − Scratch Start Technique

1

2

3

With Stick selected, start arc as
follows:

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.

VRD Model Only: Normal open-cir­cuit voltage is not present before elec­trode touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. This allows
electrode to touch workpiece without
overheating, sticking, or getting con­taminated.

OM-258035 Page 25

6-4. Lift-Arc™ Start Procedure

Lift-Arc Start Method

“Touch”

1

1 − 2

Seconds

Lift-Arc Start

With Lift-Arc selected, start arc
as follows:

1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten

electrode to workpiece at weld start
point. Hold electrode to
workpiece for 1-2 seconds, and

2

slowly lift electrode. Arc is formed
when electrode is lifted.

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. This allows
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.

Do NOT Strike Like A Match!

6-5. Remote 14 Receptacle Information

This unit automatically senses when a remote control is connected to the remote 14 receptacle. After connecting a remote control, the unit will
automatically adjust output control to a primary/secondary configuration. In this configuration, the AMPS control on the unit becomes the primary and
sets the maximum amperage output of the unit. The remote control becomes the secondary and provides an amperage range adjustment of 0 to 100%
based on the AMPS control setting.

AJ

K

B

L

NH

C

M

D

F

E

I

G

15 VOLTS DC

REMOTE
OUTPUT

CONTROL

Socket* Socket Information

A 15 volts dc (not functional).

B Contact closure to A completes 15 volts dc

contactor control circuit (not functional).

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

D Remote control circuit common.

E 0 to +10 volts dc input command signal from

remote control.

K Chassis common.

*The remaining sockets are not used.

258 649-A

GND

6-6. Fan-On-Demand

This unit is equipped with Fan-On-Demand. The fan operates only when necessary to cool internal components. At power down, the fan will operate for
a short period of time while the output indicator light is flashing.

6-7. Rack Mounting

This unit is capable of being rack mounted. See rack Owner’s Manual, OM-221611.
OM-258035 Page 26

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

Every
3
Months

Every
6
Months

! Disconnect power before

maintaining.

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

 Unreadable Labels  Weld Terminals  Damaged Gas Hose

 Damaged Weld Cables  Damaged Cords  Damaged Torch Cable

OR

 Inside Unit

! Do not remove case

when blowing out in­side of unit
(see Section 7-2) .

 Maintain more often during severe

conditions.

Reference

7-2. Blowing Out Inside Of Unit

! Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow
through front and back louvers as
shown.

258 649-A

OM-258035 Page 27

7-3. Troubleshooting

1

2

Repeated LED Flashes Indicate
Status

Display

Code

H09

H01

H06 6 0 1 No weld output.

H04 4 0 8 No weld output.

Blue Yellow

None (Prior to
MA050280G)

Alternating

Blue And

Yellow
(Eff w/

MA050280G)

Flashes

Continuously

None

(Prior to

MA050280G)

Alternating

Blue And

Yellow

(Eff w/

MA050280G)

0 7 No weld output. Not ready.

OM-258035 Page 28

Red

(LED1

On

PC13)

None

12

Trouble Possible Causes Remedy

No weld output;

unit completely

inoperative.

No weld output;

unit completely

inoperative.

Line Disconnect open.

Improper input connections.

Incorrect input voltage depending on
Voltage Selection Switch position. PTC1
and PTC2 on PC2 overheated due to when
unit was turned on.

Process Select switch is between posi­tions.

Line voltage too high or
too low.

Unit is linked incorrectly.

Buss voltage imbalance.

No primary lfb.

Faulty output diode(s) D1
or D2.

Over-current
fault.

Over-voltage
latch.

Faulty boost inductor L3.

Faulty HD1. Replace HD1 if necessary.
Open connection between

HD1 and PC1 or PC13.
Faulty PC13. Replace PC13.
Faulty PC2 (239001 or

245857)

Shorted boost relay CR1.

Boost relay CR1 does not
de−energize after ter­mination of weld.

Voltage in excess of 100V
from another source ap­plied across output studs.

1 Output LED (Blue)
2 High Temperature LED

(Yellow)

258 649-A

Place line disconnect switch in on
position
(see Section 5-9 or 5-10).

Check for proper input
connections
(see Section 5-9 or 5-10).

Turn off welding power source,
open rear switch cover, and turn
Voltage Selection Switch to correct
input voltage. Allow a 10 minute
cooling down period before turning
welding power source back on
again.

Verify Process Select switch is not
between positions.

Line voltage must be ±10%.

Check line voltage and link
accordingly.

Check DC buss caps and PC2, and
replace if necessary.

Check CT1 and wiring for an open
condition.

Check for shorts or opens in wiring.

Replace boost inductor L3 if
necessary.

Inspect all wiring and
connections.

Replace PC2.

Check for a shorted relay CR1 or
wiring.

Check PC13.

Check for external voltage sources.

7-3. Troubleshooting (Continued)

Repeated LED Flashes Indicate
Status

Display

Code

H05 5 0 11

H02 2 0 6

H03 3 0 10 No weld output. Remote trigger has been left on.

H07 0

H08 0

Blue Yellow

On

continuously

Flashes

continuously

N/A N/A N/A

N/A N/A N/A

N/A N/A N/A

N/A N/A N/A Wandering arc.

N/A N/A N/A

Red

(LED1

On

PC13)

3

5

0

2

4

9

Trouble Possible Causes Remedy

Vfb leads not connected
or reversed.

No weld output.

Low OCV

initially, but

when load is

applied LEDs

begin to flash.

Reduced weld

output.

No weld output.

No weld output.

Fan not

operating.

Fan cycles on

and off.

Erratic or

improper weld

output.

Tungsten

electrode

oxidizing and

not remaining

bright after

conclusion of

weld.

Voltage loss.

Output
foldback due
to excessive
input
current.

Unit over­heated.

Thermistor
failure.

Blocked fan.

Fan failure.

Faulty PC13. Replace PC13.

Over voltage condition.

Faulty voltage sense circuit on PC2. Replace PC2.

Weld cables too small or defective.

Dirty or loose connections.

Improper tungsten.

Worn or defective tungsten.

Gas flow too high.

Gas is blown away from weld zone. Shield weld zone from drafts.

Inadequate postflow time.

Loose or leaking gas fittings.

Water in torch. Refer to torch manual.

Short circuit across output
studs.

Faulty IGBT PM1 or PM2
on PC2.

Faulty PC13. Replace PC13.

Faulty PM1 or PM2 on
PC2 .

Faulty C3. Replace C3.

Single phase rating
exceeded.

High output VA coupled
with a low 230V line.

Primary (IGBT) thermistor
over temperature in PM1
or PM2 on PC2.

Secondary thermistor
over temperature on
output diode heatsink.

Shorted primary (IGBT)
thermistor in PM1 or PM2
on PC2.

Open primary (IGBT)
thermistor in PM1 or PM2
on PC2.

Open secondary
thermistor on output diode
heatsink.

Shorted secondary
thermistor on output diode
heatsink.

Check Vfb leads for proper wiring
and connection to output studs and
PC13.

Check for shorts.

Check PC2 and replace if
necessary.

Replace PC2.

Reduce output to 200 amperes or
less.

Check line voltage and weld
settings.

Remove trigger, wait approximately
5 seconds, and restart.

Allow unit to cool down.
Retorque PM1, PM2, and PM3
mounting hardware to 25 in lbs
(2.8 Nm).

Check IGBT PM1 and PM2
thermistors on PC2 for shorts.

Check IGBT PM1 and PM2
thermistors on PC2 and associated
wiring for opens.

Check thermistor on output
heatsink and associated wiring for
opens.

Check thermistor on output
heatsink and associated wiring for
shorts.

Check for and remove anything
blocking fan movement.

Have factory authorized service
agent check fan motor.

Check primary voltage and Voltage
Selection switch.

Use proper size and type of weld
cables (see Section 5-2).

Clean and tighten all weld cable
connections
(see Section 5-4 or 5-5).

Use proper size tungsten
(see Section 9-1).

Use properly prepared tungsten
(see Section 9).

Reduce gas flow rate
(see Section 5-4).

Allow adequate postflow time to
shield tungsten while it is cooling
after welding stops.

Check and tighten all gas fittings
(see Section 5-4).

OM-258035 Page 29

LED Status Remedy

D2

(Secondary Power)

D42

(Ready)

D43

(Capacitor Over-voltage)

D44

(Primary Power)

PC2 LED Diagnosis (For PC Board 239001 Or 245857)

Transformer T3 secondary voltage is up when lit. If not lit, contact factory authorized service

Status of precharge bus voltage and line voltage.
Precharge should be completed when lit.

490 VDC or greater on one or both bus capacitors
when lit.

Transformer T3 primary control voltage is up when lit. If not lit, contact factory authorized service

agent.
If not lit, contact factory authorized service

agent.
If lit, contact factory authorized service agent.

agent.

OM-258035 Page 30

Notes

OM-258035 Page 31

SECTION 8 − ELECTRICAL DIAGRAMS

OM-258035 Page 32

Figure 8-1. Circuit Diagram

257 672-D

OM-258035 Page 33

SECTION 9 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2013-10

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

9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)

 Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference

the product packaging to identify the tungsten you are using.

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

.010 in. (.25 mm) Up to 25 Up to 20
.020 in. (.50 mm) 15-40 15-35

.040 in. (1 mm) 25-85 20-80
1/16 in. (1.6 mm) 50-160 50-150
3/32 in. (2.4 mm) 130-250 135-235

1/8 in. (3.2 mm) 250-400 225-360

5/32 in. (4.0 mm) 400-500 300-450

3/16 in (4.8 mm) 500-750 400-500

1/4 in. (6.4 mm) 750-1000 600-800

Balance Control @ 65% Electrode Negative

♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

AC − Argon

(For Use With Aluminum)

9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines

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.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

OM-258035 Page 34

2-1/2 Times

Electrode Diameter

2

4

Ideal Tungsten Preparation − Stable Arc

1 Grinding Wheel
Grind end of tungsten on fine grit, hard

3

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

1

2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage

capacity.
4 Straight Ground
Grind lengthwise, not radial.

SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW)

10-1. Positioning The Torch

! 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 cerium or lantha­num based tungsten instead of
thoriated. Thorium dust 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.

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 Section 9.

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°

2

1

10−15°

4

3/16 in.

Bottom View Of Gas Cup

90°

5

3

4

5

6

6

1/16 in.

Ref. ST-161 892

OM-258035 Page 35

10-2. 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°

75°

15°

Move torch to front

of pool. Repeat process.

10-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead

of pool. Repeat process.

ST-162 002-B

“T” Joint

90°

20-40°

30°

20°

15°

Lap Joint

70°

75°

90°

10°

15°

20°

75°

15°

Corner Joint

75°

ST-162 003 / S-0792

OM-258035 Page 36

Notes

OM-258035 Page 37

SECTION 11 − PARTS LIST

 Hardware is common and

not available unless listed.

13

12

21

16

10

23

18

17

22

15

11

13

20

7

9

6

14

8

15

25

3

19

4

16

24

1

26

5

2

258650-C

OM-258035 Page 38

Figure 11-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

1 Fig 11-2 Panel, Front W/Cmpnt 1... .......... .. ...............................................

2 Fig 11-3 Panel, Rear W/Cmpnt 1... .......... .. ...............................................

3 Fig 11-4 Magnetics Subassembly 1... .......... .. .............................................

4 Fig 11-6 Heat Sink Assembly, Output Diode 1... .......... .. ....................................

5 238999 Base Assy 1... .......... .. .........................................................

6 269291 Bracket, Mtg Capacitors 1... .......... .. ..............................................

7 206038 Heat Sink Assembly, Input 1... .......... .. ............................................

8 +217216 Wrapper 1... ......... .. ...........................................................

274964 Label, Warning General Precautionary (En/Fr/Sp) 1................ .. .......................

9 +207437 Cable, Power 6 ft 10ga 4c Blk/Red/Wht/Grnyel 1... ......... .. ..........................

182826 Label, Warning Electric Shock Power Cord 1................ .. .............................

10 206108 Handle, Rubberized Carrying 1... .......... .. .........................................

11 206289 Link, Connecting 4... .......... .. ....................................................

12 PLG3,6 206247 Plugs, W/Leads 2... . .. .....................................................

13 PLG4,7 206254 Plugs, W/Leads 2... . .. .....................................................

14 196231 Xfmr, Current Sensing 200/1 1... .......... .. ..........................................

15 206270 Insulator, Side 2... .......... .. ......................................................

16 PLG5 206276 Cable, LEM W/Plugs 1... .. . .. ................................................

17 C1,C2 +203912 Capacitor, Elctlt 2400 uf 500 VDC Can 2.5 Dia 2... .. .. ..........................

126026 Label, Warning Electric Shock Can Kill Significant 2................ .. .......................

18 205908 Clamp, Capacitor 2.500 Dia Horizontal Mtg Nylon 1... .......... .. .......................

19 232856 Rail, Heat Sink 2... .......... .. ......................................................

20 PC2 244500 Kit, Circuit Card Assy Interconnect 1... ... .. .. ....................................

21 PC13 243436 Circuit Card Assy, Control W/Program 1... .. . .. .................................

21 PC13 246930 Circuit Card Assy, Control W/Program VRD Model 1... .. .. .......................

22 229337 Screw, M 5− .8x 12 Soc Hd−Torx Stl Pld Sems 6... .......... .. ..........................

23 252661 Washer, Spring 5 mm Din 137B Stl Zc Plated 2... .......... .. ...........................

24 229333 Screw, M10−1.5 x 20 Hex Hd−pln 8.8 Pld Sems 2... .......... .. .........................

25 Fig 11-5 Switch Assy, Relinking 1... .......... .. ...............................................

26 C7,C8 222488 Capacitor Assy 2... .. . .. .....................................................

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
VRD Models only.

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-258035 Page 39

 Hardware is common and

not available unless listed.

2

17

21

22

6

5

20

19

18

1

4

8

13

12

11

14

3

16

10

7

9

15

258 652-B

Figure 11-2. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-2. Panel, Front w/Components

1 194242 Panel, Front/Rear 1... .......... .. ...................................................

2 257572 Panel, Front Upper 1... .......... .. .................................................

3 195647 Panel, Front Lower 1... .......... .. .................................................

4 S1 207165 Switch, w/Leads 1... .... .. .. ....................................................

5 174991 Knob, Pointer 1.250 Dia x .250 ID w/Spring Clip−.21 1... .......... .. .....................

6 174992 Knob, Pointer .840 Dia X .250 ID w/Spring Clip−.21 1... .......... .. ......................

7 RC14 207144 Receptacle w/Leads & Plug(14 Pin) 1... .. . .. ....................................

8 253430 Terminal, Connector Friction 2... .......... .. ..........................................

218183 Rcpt Assy, Tw Lk Insul Fem (Tweco Type) (Including) 2................ .. ....................

202813 Receptacle, Twist Lock Power Assy (Dinse Type) (Including) 2................ .. ..............

209473 Receptacle, Twist Lock Tweco (Female) 2................ ... ..............................

9 202553 Receptacle, Twist Lock Dinse (Female) 2... .......... ... ...............................

10 185712 Insulator, Bulkhead Front 2... .......... ... ...........................................

11 185713 Insulator, Bulkhead Rear 2... .......... ... ...........................................

12 185714 Washer, Tooth 22 mm ID X 31.5 mm OD 1.310−1 mm T Intern 2... .......... ... ..........

13 185717 Nut, M20−1.5 1.06 Hex .19h Brs Locking 2... .......... ... .............................

14 185718 O−ring, 0.989 ID x 0.070 H 2... .......... ... .........................................

15 186228 O−ring, 0.739 ID x 0.070 H 2... .......... ... .........................................

16 207253 Blank, Hex Hole Black 1... .......... .. ...............................................

17 257571 Nameplate, Miller CST 280 w/Meter 1... .......... .. ...................................

17 257907 Nameplate, Miller CST 280 w/Meter VRD 1... ......... .. ...............................

18 PC4 257391 Circuit Card Assy, Operator Interface 1... ... .. .. ..................................

19 170391 Connector, Circ Ms Protective Cap 1... .......... .. ....................................

20 178355 Nut, 375−32 .54 Hex .25h Nyl Flange .62D 2... .......... .. .............................

21 209554 Screw, KA 35 x 8 Pan Hd−phl 2... .......... .. .........................................

22 230485 Knob, Switch 1... .......... .. .......................................................

257125 Bracket Assy, Mtg User Interface 1................ .. ......................................

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
VRD Models only.

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-258035 Page 40

 Hardware is common and

not available unless listed.

7

5

6

4

6

1

3

2

803 948-B

Figure 11-3. Panel, Rear w/Components

Item
No.

Part
No. Description Quantity

Figure 11-3. Panel, Rear w/Components

1 194242 Panel, Front/Rear 1... .......... .. ...................................................

2 206053 Panel, Rear Lower 1... .......... .. ..................................................

287132 Label, Notice Cst If Front Panel Lamps Do Not Light 1................ .. .....................

3 210128 Bracket, Heatsink 1... .......... .. ...................................................

4 145217 Screw, K40x 12 Pan Hd−Phl 2... .......... .. ..........................................

5 207253 Blank, Hex Hole Black 1... .......... .. ...............................................

6 264099 Bushing, Strain Relief .450/.709 ID x 1.068 Mtg Hole 1... .......... .. ....................

7 246319 Insulator, Switch Rear Panel CST−280 (Not Shown) 1... .......... .. .....................

VRD Models only.

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-258035 Page 41

 Hardware is common and

not available unless listed.

11

10

8

7

3

8

13

9

6

4

5

12

1

8

2

14

Figure 11-4. Magnetics Subassembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-4. Magnetics Subassembly

1 206063 Panel, Plenum 1... .......... .. ......................................................

2 T1 212812 Xfmr, HF Litz/Litz w/Boost (208−230/400−460 Models) 1... .... .. .. ...................

2 T1 206065 Xfmr, HF Litz/Litz w/Boost (220−230/460−575 Model) 1... .... .. .. ....................

3 FM 239380 Fan, Muffin 24VDC 3200 RPM 141 CFM 4.125 Mtg Holes 1... ... .. .. ................

4 Z1 206064 Inductor, Output 1... .... .. .. .....................................................

5 CR1 206258 Relay, Encl 24VDC SPST 30A/240VAC 4 Pin Flange Mtg 1... ... .. .. .................

6 R3 206281 Resistor, w/Leads 1... .... .. .. ...................................................

7 C3 196143 Capacitor, Polyp Met Film 16. uf 400 VAC 10% 1... .... .. .. ..........................

8 057357 Bushing, Snap−in Nyl .937 ID X 1.125 Mtg Hole 3... .......... .. .........................

9 L3 225189 Coil, Inductor (Boost) 1... .... .. .. ................................................

10 198634 Bracket, Front Heatsink Mtg 1... .......... .. ..........................................

11 083147 Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High 1... .......... .. ...................

12 136343 Screw, K50 x 20 Pan Hd−Phl 2... .......... .. .........................................

13 170647 Bushing, Snap−in Nyl 1.312 ID X 1.500 Mtg Hole 1... .......... .. ........................

14 227746 Gasket, Inductor Mounting 1... .......... .. ...........................................

804 206-B

Quantity

VRD Models only.

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-258035 Page 42

 Hardware is common and

not available unless listed.

1

6

7

5

4

2

3

803 949-B

Figure 11-5. Relinking Switch And Door Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-5. Relinking Switch And Door Assembly

1 +217252 Door Assy, Relinking 1... ......... .. .................................................

228702 Label, Switch Position 208−230/400−460 VAC (208−230/400−460 Models) 1................ .. ..

228675 Label, Switch Position 220−230/460−575 VAC (220−230/460−575 Model) 1................ .. ...

221462 Label, Caution Operating Link Switch Etc 1................ .. ...............................

2 217647 Switch, Rotary 3 Posn 4P 32A 600V 180 Deg (Spl) 1... .......... .. ......................

3 209554 Screw, KA 35 x 8 Pan Hd−Phl 2... .......... .. ........................................

4 221573 Nut, Speed Snap−in 1/4 Turn 2... .......... .. .........................................

5 221575 Retainer, Nylon Push−On 2... .......... .. ............................................

6 221574 Screw, 1/4 Turn Oval Hd−Phl 2... .......... .. .........................................

7 230485 Knob, Switch 1... .......... .. .......................................................

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
VRD Models only.

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-258035 Page 43

 Hardware is common and

not available unless listed.

10

9

11

11

4

6

5

2

8

3

7

1

803 159-E

Figure 11-6. Heat Sink Assembly, Output Diode

Diagram

Item
No.

marking

Part
No. Description

Quantity

Figure 11-6. Heat Sink Assembly, Output Diode

1 205916 Heat Sink, Diode Output 1... .......... .. .............................................

2 D1,D2 223422 Kit, Diode Ultra−fast Recovery 2... .. . .. ........................................

3 SR1 201530 Kit, Diode Fast Recovery Bridge 1... ... .. .. ......................................

4 HD1 191941 Transducer, Current 1... ... .. .. .................................................

5 R1,C5 207384 Resistor/Capacitor 1... .. . .. ..................................................

6 RT1 209223 Thermistor, NTC 30k Ohm @ 25 Deg C 18in Lead 1... ... .. .. ......................

7 049611 Tubing, Cop .540 OD x .123 Wall x .687 1... ........... .. ................................

8 207932 Insulator, Heatsink 1... .......... .. ..................................................

9 108942 Screw, 250−20 x1.25 Hexwhd .61D Gr5 Pld 1... .......... .. ............................

10 602062 Screw, 004−40 x .37 Pan Hd−Phl Stl Pld Cone Sems 5... .......... .. ....................

11 207451 Screw, 008−32 x .50 Pan Hd−Phl Stl Pld Sems 7... .......... .. .........................

VRD Models only.

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-258035 Page 44

 Hardware is common and

y

not available unless listed.

2

3

4

1

803 162-C

Figure 11-7. Heat Sink Assembly, Input

Diagram

Item
No.

marking

Part
No. Description

Quantit

Figure 11-7. Heat Sink Assembly, Input

1 205915 Heat Sink, IGBT/Input Rectifier Module 1... .......... .. ................................

2 206091 Bracket, Heatsink Rear 1... .......... .. ..............................................

3 TE1 206328 Block, Term 70 Amp 3 Pole Screw Term 4−14 Wire 1... ... .. .. ......................

4 244674 Insulator, Terminal Block 1... .......... .. .............................................

VRD Models only.

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-258035 Page 45

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)

18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)

1/8 in. (.125 in.)

3/16 in. (.188 in.)

1/4 in. (.25 in.)

5/16 in. (.313 in.)

3/8 in. (.375 in.)

1/2 in. (.5 in.)

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2016

(Equipment with a serial number preface of MG or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective
date of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed. If notification is submitted as an online warranty claim, the
claim must include a detailed description of the fault and the
troubleshooting steps taken to identify failed components and the
cause of their failure.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.

1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)

* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)

* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Torches
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Miller, 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
Miller, 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.

MILLER 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 Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. 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 MILLER 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 MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply 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.

miller_warr 2016-01

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

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

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

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.