Miller Maxstar 200 SD, Maxstar 200 DX, Maxstar 200 LX Owner's Manual

OM-2226 189783AL

2010−04

Processes

TIG (GTAW) Welding

Stick (SMAW) Welding

Description

115/230/400/460 Volt Models W/AutolineR

Arc Welding Power Source

R

Maxstar 200 SD, DX, And LX

(Including Optional Cart And Cooler)

CE And Non-CE Models

Visit our website at

www.MillerWelds.com

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 9001:2000 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 9..........................................................

2-6. Informations relatives aux CEM 9.........................................................

SECTION 3 − DEFINITIONS (CE Models) 11........................................................

3-1. Warning Label Definitions 11..............................................................

3-2. WEEE Label (For Products Sold Within The EU) 12...........................................

3-3. Symbols And Definitions 13...............................................................

SECTION 4 − INSTALLATION 14..................................................................

4-1. Important Information Regarding CE Products (Sold Within The EU) 14...........................

4-2. Serial Number And Rating Label Location 14.................................................

4-3. Specifications 15........................................................................

4-4. Volt-Ampere Curves 16...................................................................

4-5. Duty Cycle And Overheating 17............................................................

4-6. Selecting A Location 18...................................................................

4-7. Weld Output Terminals And Selecting Cable Sizes* 19.........................................

4-8. Remote 14 Receptacle Information 20.......................................................

4-9. Automation 10-Pin Connection (LX Models) 21...............................................

4-10. Typical Automation Application 21..........................................................

4-11. Gas Connections 22.....................................................................

4-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections 22...............

4-13. Stick DCEP (Direct Current Electrode Positive) Connections 23.................................

4-14. TIGRunner Connections 24...............................................................

4-15. Electrical Service Guide 25................................................................

4-16. Connecting Input Power 26................................................................

SECTION 5 − OPERATION 28....................................................................

5-1. Controls 28.............................................................................

5-2. Encoder Control 29......................................................................

5-3. Amperage Control 29.....................................................................

5-4. Ammeter And Parameter Display 29........................................................

5-5. Voltmeter 30............................................................................

5-6. Process Control 30......................................................................

5-7. Lift-ArcE And HF TIG Start Procedures 31...................................................

5-8. Output Control 32........................................................................

5-9. Pulser Control (DX And LX Models) 33......................................................

5-10. Sequencer Controls (DX Models Only) 34...................................................

5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) 35............................................

5-12. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) 36...........................

5-13. Factory Parameter Defaults And Range And Resolution 36.....................................

5-14. Resetting Unit To Factory Default Settings (All Models) 37......................................

5-15. Arc Timer/Counter Display 38..............................................................

TABLE OF CONTENTS

SECTION 6 − ADVANCED FUNCTIONS 39.........................................................

6-1. Accessing Advanced Functions 39.........................................................

6-2. Programmable TIG Start Parameters 40.....................................................

6-3. Output Control And Trigger Functions 44....................................................

6-4. Setting Preflow Time 50...................................................................

6-5. Stick Open-Circuit Voltage (OCV) Selection 50...............................................

6-6. Stick Stuck Check Selection 50............................................................

6-7. Lockout Functions 51....................................................................

6-8. Setting Unit To Display PPP While Pulse Welding (DX Models Only) 53...........................

6-9. External Pulse Control 53.................................................................

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 54........................................

7-1. Routine Maintenance 54..................................................................

7-2. Blowing Out Inside Of Unit 55..............................................................

7-3. Voltmeter/Ammeter Help Displays 56.......................................................

7-4. Troubleshooting 57......................................................................

SECTION 8 − ELECTRICAL DIAGRAMS 59........................................................

SECTION 9 − HIGH FREQUENCY (HF) 60..........................................................

9-1. Welding Processes Requiring High Frequency 60.............................................

9-2. Correct Installation 60....................................................................

SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING 61.......................................

10-1. DC - GTAW 16 Gauge Stainless Steel Set-Up 61.............................................

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER

MACHINES 62..................................................................................

11-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 62........

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter

Machines 62............................................................................

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 63.........................................

12-1. Positioning The Torch 63..................................................................

12-2. Torch Movement During Welding 64........................................................

12-3. Positioning Torch Tungsten For Various Weld Joints 64........................................

SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING 65.....................................

13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 65.......................

SECTION 14 − STICK WELDING (SMAW) GUIDELINES 66...........................................

SECTION 15 − PARTS LIST 74...................................................................

SECTION 16 − COOLER PARTS LIST 84...........................................................

SECTION 17 − CART PARTS LIST 86..............................................................

OPTIONS AND ACCESSORIES
WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

Maxstar 200 DX 907354

MAXSTAR 200 DX W/CROWBAR, CE

(NSPR)

Council Directives:

S 2006/95/EC Low Voltage

S 2004/108/EC Electromagnetic Compatibility

Standards:

S IEC 609741:2005 Arc welding equipment – Part 1: Welding power sources

907354001

S IEC 609743:2007 Arc welding equipment – Part 3: Arc striking and stabilizing devices

S IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements

S EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,

arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)

US Signatory:

August 22, 2009

__________________________________________________________________________

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

Date of Declaration

241515B

Notes

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

som _2010−03

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.

D Do not touch live electrical parts.

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

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

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

there is a danger of falling.

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

unit.

D 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!

D Disconnect input power or stop engine before installing or

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

. 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.

D Properly install and ground this equipment according to its

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

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

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

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

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

replace cord immediately if damaged − bare wiring can kill.

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

with a separate cable.

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

or another electrode from a different machine.

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

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

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

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

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

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

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

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-2226 Page 1

FUMES AND GASES can be hazardous.

)

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

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

arc to remove welding fumes and gases.

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

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

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

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

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

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

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

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and 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.

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

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

glowing embers, and flames.

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

pass them.

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

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

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

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

D Wear 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).

D Wear approved safety glasses with side shields under your

helmet.

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

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

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

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

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

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

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

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

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

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

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

D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

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

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

D Do not use welder to thaw frozen pipes.

OM-2226 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect ImplantedMedical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D 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.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

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

D Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

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

ber of persons to lift and move cylinders.

D 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.

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

combustible surfaces.

D Do not install unit near flammables.

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

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

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

extend beyond opposite side of unit.

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

when working from an aerial location.

D 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

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

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

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

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

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

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

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

MOVING PARTS can injure.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D 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.

D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

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

ly correct any interference problem resulting from the installa­tion.

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

equipment at once.

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

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

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

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

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

OM-2226 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.)

Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

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.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
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).

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, 4221 Walney Road, 5th Floor,
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
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

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).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: [phone], website:
www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may inter­fere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or 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-2226 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

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.

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

. 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.

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.

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

sans trous.

D 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.

D 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.

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

MENT si le procédé de soudage le demande.

D 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 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 !

D 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).

D Installer le poste correctement et le mettre à la terre convenable-

ment selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.

D 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.

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

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

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

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

D Vérifier fréquemment le cordon d’alimentation afin de s’assurer

qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.

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

sante ou mal épissés.

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

avec un câble distinct.

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

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

D Ne pas toucher des porte électrodes connectés à deux machines

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

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

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

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

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

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

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

contact avec tout objet métallique.

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

masse à une même borne de sortie de soudage.

fre_som_2010−03

OM-2226 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans

s

e

­r

e

e

les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D 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.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher à mains nues les partie

chaudes.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
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.

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D 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.

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

approuvé.

D Lire et comprendre les spécifications de sécurité des matériaux

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

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

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

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

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

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

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et 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 soudag

génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
soudage.

D 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).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D 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.

D Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

OM-2226 Page 6

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

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

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

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

D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

D 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.

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

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

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

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D 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.

provoquer leur éclatement. Des étincelles peuvent

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

D 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.

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

facial.

LES ACCUMULATIONS DE GAZ

t

a
e

r

e

-

risquent de provoquer des blessures

ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas

de non-utilisation.

D Veiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction
d’air homologué.

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

D Les porteurs de stimulateurs cardiaques

et autres implants médicaux doivent rester
à distance.

D 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.

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

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

soudage, les manipuler avec précaution.

D 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.

D 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.

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

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

une bouteille.

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

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

D Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

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

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

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

samment de personnes pour soulever et déplacer les bouteilles.

D 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.

de gaz font normalement partie du procédé de

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

Risque D’INCENDIE OU

D’EXPLOSION.

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

à proximité de surfaces inflammables.

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

duits inflammables.

D 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.

D Utiliser l’anneau de levage uniquement pour

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

D Utiliser un équipement de levage de capacité

suffisante pour lever l’appareil.

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

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

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

mobiles lors de toute opération en hauteur.

D 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.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage e

les yeux.

D Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cett
manœuvre est à exécuter dans un endroit sû
lorsque l’on porte l’équipement homologué d
protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antista-

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

OM-2226 Page 7

Les PIÈCES MOBILES peuvent

causer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

Les PIÈCES MOBILES peuvent

causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de
protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de

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

D Remettre les portes, panneaux, recouvrements ou dispositifs de

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

LIRE LES INSTRUCTIONS.

D 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.

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

constructeur.

D Effectuer l’entretien en respectant les manuels d’utilisation, les

normes industrielles et les codes nationaux, d’état et locaux.

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

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

provoquer des interférences avec les équi­pements de radio−navigation et de com­munication, les services de sécurité et les ordi­nateurs.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa­tion.

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

qualifié les interférences résultant de l’installation.

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

pareil.

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

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

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

D 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.

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

compatible électromagnétiquement.

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

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

D Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

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

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précéden-

tes, 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.

2-4. Proposition californienne 65 Avertissements

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)

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu­lation.

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent

OM-2226 Page 8

Pour les moteurs à essence :

Pour les moteurs diesel :

des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global

Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec­tion Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan­tilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).

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

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques 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
câbles d’un côté et à distance de l’opérateur.

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

25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).

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

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site inter­net : www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
www.cdc.gov/NIOSH).

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.

OM-2226 Page 9

OM-2226 Page 10

SECTION 3 − DEFINITIONS (CE Models)

3-1. Warning Label Definitions

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

1 Electric shock from welding electrode

or wiring can kill.

1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.

1.3 Disconnect input plug or power before
working on machine.

2 Breathing welding fumes can be

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust

2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion

3.1 Keep flammables away from welding.

3.2 Welding sparks can cause fires. Have

1 1.1 1.2 1.3

hazardous to your health.

to remove the fumes.

or fire.

Do not weld near flammables.

a fire extinguisher nearby, and have a
watchperson ready to use it.

4 4.1

3.3 Do not weld on drums or any closed
containers.

4 Arc rays can burn eyes and injure

skin.

4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the
machine or welding.

6 Do not remove or paint over (cover)

the label.

2 2.1 2.2 2.3

3 3.1 3.2 3.3

5

6

S-179 310-A

OM-2226 Page 11

1

6 7

2

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

1 Electric shock from wiring can

kill.

2 Disconnect input plug or

power before working on

3

V

> 60 s

8

45

V

V

S-185 836

9

machine.

3 Hazardous voltage remains

on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.

4 Always wait 60 seconds after

power is turned off before
working on unit, OR

5 Check input capacitor voltage,

and be sure it is near 0 before
touching any parts.

6 When power is applied failed

parts can explode or cause
other parts to explode.

7 Flying pieces of parts can

cause injury. Always wear a
face shield when servicing
unit.

8 Always wear long sleeves and

button your collar when
servicing unit.

9 After taking proper

precautions as shown,
connect power to unit.

1

∠ = <60

∠

2345

°

S-179 309-A

3-2. WEEE Label (For Products Sold Within The EU)

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Falling equipment can cause

injury and damage to unit.

3 Always lift and support unit

using both handles. Keep
angle of lifting device less
than 60 degrees.

4 Use a proper cart to move

unit.

5 Do not use one handle to lift

or support unit.

1/96

Do not discard product (where ap­plicable) with general waste.

Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec­tion facility.

Contact your local recycling office
or your local distributor for further
information.

OM-2226 Page 12

3-3. Symbols And Definitions

A
V

X

U

1

Amperes Panel−Local

Volts Voltage Input

Voltage Output Circuit Breaker Remote

Protective Earth

(Ground)

On Off Positive Negative

Alternating

Current

Duty Cycle Direct Current Line Connection

Primary Voltage

IP

Postflow Timer Preflow Timer

Gas Input Gas Output

Degree Of
Protection

I

1max

Gas Tungsten Arc

Welding (GTAW)

3 Phase Static Frequency

Converter-Transformer-Rectifier

Rated Maximum

Supply Current

S

I

U

I

1eff

2

2

Shielded Metal Arc

Welding (SMAW)

Lift-Arc Start

(GTAW)

Seconds

Rated Welding

Current

Conventional Load

Voltage

Maximum Effective

Supply Current

U

0

Hz

Rated No Load

Voltage (Average)

Normal Trigger Op-

eration (GTAW)

Hertz

Final Slope Final Amperage

Contactor Control

(Stick)

Background Amps Process Pulser Sequence

Output Adjust

Pulse Background

Amperage

Two-Step Trigger

Operation (GTAW)

Recall From

Memory

Pulser On-Off

S

Initial Amperage

Four-Step Trigger

Operation (GTAW)

Arc Force (DIG)

Pulse Percent

On Time

TIG Weld Amps

And Peak Amps

While Pulsing

Suitable For Areas

Of Increased

Shock Hazard

Increase/Decrease

Of Quantity

Percent

HF Impulse Start-

ing (GTAW)

Initial Slope

Pulse Frequency

OM-2226 Page 13

SECTION 4 − INSTALLATION

4-1. Important Information Regarding CE Products (Sold Within The EU)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.

This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.

S The EMF assessment on this equipment was conducted at 0.5 meter.
S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.

4-2. Serial Number And Rating Label Location

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

OM-2226 Page 14

4-3. Specifications

Input Power Rated Output

Three-Phase

Stick Process

Three-Phase
TIG Process

Three-Phase

Stick Process

Three-Phase
TIG Process

Single-Phase

Stick Process

Single-Phase

TIG Process

150 A @ 26

VDC,

60% Duty

Cycle

175 A @ 17

VDC,

60% Duty

Cycle

200 A @ 28

VDC, 30%
Duty Cycle

200 A @ 18

VDC, 40%
Duty Cycle

150 A @ 26

VDC,

60% Duty

Cycle

175 A @ 17

VDC,

60% Duty

Cycle

Welding

Amperage

Range

1 − 200

1 − 200

1 − 200

1 − 200

1 − 200

1 − 200

Max.

Open-Cir-

cuit Voltage

(U0)

80∇

9-14♦

80

9-14♦

80∇

9-14♦

80

9-14♦

80∇

9-14♦

80

9-14♦

Rated Peak Strik-

ing Voltage (Up)

15 KV**

15 KV** -−

15 KV** 18.4

15 KV**

15 KV**

15 KV**

Amperes Input At Rated Output,

115 230 400 460

-−

-−

-−

13.1

0.16*

10.5

0.16*

0.16*

12.7

0.16*

21.7

0.23*

17.4

0.23*

50/60Hz

7.4

0.24*

6.0

0.24*

10.3

0.24*

7.2

0.24*

-−

-−

6.4

0.25*

5.2

0.25*

8.9

0.25*

6.2

0.25*

10.6
.25*

8.5

.25*

KVA KW

5.2

0.06*

4.2

0.06*

7.3

0.06*

5.1

0.06*

5.0

0.05*

4.0

0.05*

5.0

0.03*

4.0

0.03*

7.0

0.03*

4.9

0.03*

5.0

0.02*

4.0

0.02*

Single-Phase

Stick Process

Single-Phase

TIG Process

Single-Phase

Stick Process

Single-Phase

TIG Process

*While idling
** Arc starting device is designed for manual guided operations.

125 A @ 25

VDC,

50% Duty

Cycle

150 A @ 16

VDC,

70% Duty

Cycle

100 A @ 24

VDC,

80% Duty

Cycle

125 A @ 15

VDC,

100% Duty

Cycle

1 − 200

1 − 200

1 − 200

1 − 200

80∇

9-14♦

80

9-14♦

80∇

9-14♦

80

9-14♦

15 KV**

15 KV**

15 KV**

15 KV**

34.1

0.42*

29.7

0.42*

28.1

0.42*

23.0

0.42*

-−

-−

-− -− -−

-− -− -−

-− -−

-− -−

0.05*

0.05*

0.05*

0.05*

♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.

∇Normal open-circuit voltage (80 volts) is present while in Stick with normal open-circuit voltage selected.

. Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.

.

This unit is equipped with Auto-Linet. The Auto-Line circuitry automatically connects to 120−460 VAC, single- or three-phase power with­out removing the cover to relink the power source.

4.0

3.4

3.2

2.6

3.8

0.03*

3.4

0.03*

3.2

0.03*

2.6

0.03*

OM-2226 Page 15

4-4. Volt-Ampere Curves

140

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

115VAC Input

120

100

80

Volts

60

40

Stick/TIG Min

20

0

0 50 100 150 200 250

140

120

100

80

Stick Max

TIG Max

DIG Max

Amperes

Other Input Voltages

Stick Max

TIG Max

Volts

60

40

Stick/TIG Min

20

0

0 50 100 150 200 250

*Amperage setting must be reduced to obtain currents less than highlighted data* point.

DIG Max

.

Amperes

ST- 189 767-A

OM-2226 Page 16

4-5. Duty Cycle And Overheating

90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process
125 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process

150 A @ 60% Duty Cycle For Stick Process (Other Voltages)
175 A @ 60% Duty Cycle For TIG Process (Other Voltages)

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

If unit overheats, output stops, a
Help message is displayed (see
Section 7-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.

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

Overheating

6 Minutes Welding 4 Minutes Resting

0

15

Minutes

Reduce Duty Cycle

A or V

OR

ST-189 770-A

OM-2226 Page 17

4-6. Selecting A Location

Dimensions And Weight

34.7 lb (15.7 kg) - without power cord

37.3 lb (16.9 kg) - with power cord

1 Line Disconnect Device
Locate unit near correct input

power supply.

! Special installation may be

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

17-1/4 in.
(438 mm)

13-3/8 in.
(333 mm)

7-9/16 in.

(192 mm)

Location And Airflow

1

18 in.

(460 mm)

18 in.

(460 mm)

OM-2226 Page 18

802 451

4-7. 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

! Turn off power before

connecting to weld out­put terminals.

! Do not use worn,

damaged, under­sized, or poorly
spliced cables.

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

Welding

Amperes***

100 4 (20) 4 (20) 4 (20) 3 (30)

150 3 (30) 3 (30) 2 (35) 1 (50)

200 3 (30) 2 (35) 1 (50) 1/0 (60)

+

−

Output Receptacles

* 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

***Select weld cable size for pulsing application at peak amperage value.

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)

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle

10 − 100% Duty Cycle

OM-2226 Page 19

4-8. Remote 14 Receptacle Information

AJ

K

B

L

C

D

I

NH

M

G

F

E

15 VOLTS DC

OUTPUT
CONTACTOR

REMOTE

OUTPUT

A Contactor control +15 volts DC.

B Contact closure to A completes 15 volts DC

contactor control circuit and enables output.

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

to remote control.

D Remote control circuit common.

CONTROL

Socket* Socket Information

E 0 to +10 volts DC input command signal from

remote control.

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

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

G +15 volts DC GND

K Chassis common.

* The remaining sockets are not used.

ST-802 541

A/V

AMPERAGE

VOLTAGE

GND

CHASSIS

. If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote

control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote
hand control will not function.

OM-2226 Page 20

4-9. Automation 10-Pin Connection (LX Models)

Socket Socket Information For 10-Pin Receptacle RC2

A Start/Stop

F

E

G

H

A

D

J

C

I

B

B Gas

C Output enable

D Chassis ground

E Final slope − collector

F Final slope − emitter

G Pulse lockout − collector

Ref. ST-802 458

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

B - Closure to D turns on gas. If a preflow time is entered, the preflow cycle will time out before arc initiation. If a post flow time is entered, the
post flow cycle will time out at the end of the weld, even if B to D closure is opened.

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

Outputs are isolated open-collector transistor which are able to conduct at least 60 mA of current and 27 VDC peak.

Final Slope - output is on when in Final Slope.

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

Arc On - output is on when the contactor is on and amperage is greater than 5 amps, or output voltage is greater than 5 volts but less than 50
volts.

H Pulse lockout − emitter

I Valid arc − collector

J Valid arc − emitter

Definitions Of Inputs And Outputs

Inputs

Outputs

4-10. Typical Automation Application

Typical 10-Pin Output

Collector

Emitter

Coil resistance plus R
should be chosen to

CR1

limit current to 75 mA

R

+

User supplied power
up to 27 volts DC
peak

−

CR1

To User Equipment

OM-2226 Page 21

4-11. Gas Connections

1 Gas Fitting
Fittings have 5/8-18 right-hand

threads (3/8-19 BSPP on CE units).
2 Cylinder Valve
Open valve slightly so gas flow

blows dirt from valve. Close valve.

4

1

3

2

3 Regulator/Flowmeter
4 Flow Adjust
Typical flow rate is 15 cubic feet per

hour (7.1 liters per minute).
Connect customer supplied gas

hose between regulator/flowmeter
and gas fitting on rear of unit.

Tools Needed:

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

ST-802 452

4-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections

! Turn off power before mak-

ing connections.

1 Negative (−) Weld Output

Terminal

Connect TIG torch to negative weld
output terminal.

2 Gas Out Connection
Connect torch gas hose to gas out

fitting.
3 Positive (+) Weld Output

Terminal

Connect work lead to positive weld
output terminal.

4 Remote 14 Receptacle
Connect desired remote control to

Remote 14 receptacle.

5

3

2

4

1

5 Gas In Connection
Connect gas hose from gas supply

to gas in fitting.

OM-2226 Page 22

Tools Needed:

11/16 in., (21 mm)

Ref. ST-802 471

4-13. Stick DCEP (Direct Current Electrode Positive) Connections

2

3

1

! Turn off power before mak-

ing connections.

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.

3 Remote 14 Receptacle
If desired, connect remote control

to Remote 14 receptacle (see Sec­tion 4-8).

Ref. ST-802 471

OM-2226 Page 23

4-14. TIGRunner Connections

4

3

Cart and cooler are optional equip­ment.

1 Gas Cylinder
2 Chains
Secure gas cylinder to cart with

chains.
Connect gas hose to welding power

source (see Section 4-11).
Connect work lead and torch to

welding power source (see Section
4-12).

3 Water-Out (To Torch)

1

5

6

2

Connection

Connect torch water-in (blue) hose
to welding power source water-out
connection.

4 Water-In (From Torch)

Connection

Connect torch water-out (red) hose
to welding power source water-in
connection.

5 115 Or 230 Volt AC Grounded

Receptacle (Depending On
Model)

For 115 volt models, an individual
branch circuit capable of carrying
15 amperes and protected by fuses
or circuit breakers is recom­mended. Recommended fuse or
circuit breaker size is 15 amperes.
For 230 volt models, an individual
branch circuit capable of carrying
10 amperes and protected by fuses
or circuit breakers is recom­mended. Recommended fuse or
circuit breaker size is 10 amperes.

6 Power Cord

NOTICE − Do not cut plug from 115
volt cord and attempt to rewire for
230 volts, or do not cut plug from
230 volt cord and attempt to rewire
for 115 volts.

Application

Coolant

*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37°F (-38°C) and resist algae growth.

NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.).

OM-2226 Page 24

GTAW Or Where

HF* Is Used

Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water

OK Above 32°F (0° C)

Tools Needed:

11/16 in., (21 mm for CE units)

805 338-A

4-15. Electrical Service Guide

. Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC. If actual input voltage is outside this range, unit may not operate

according to specifications.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

Single-Phase,

100% Duty

Cycle

Input Voltage (V)

Input Amperes (A) At Rated Output 25 22 13.1 7.4 6.4

Max Recommended Standard Fuse Rating In Amperes
Time Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters) 57 (17) 79 (24)

Min Grounding Conductor Size In AWG

Reference: 2008 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

310.16. 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

1

2

3

115 230 230 400 460

25 25 15 8 8

35 30 20 10 10

10 12 14 14 14

10 12 14 14 14

Single-Phase,

60% Duty

Cycle

Three-Phase, 60% Duty

102

(31)

Cycle

308
(94)

407

(124)

OM-2226 Page 25

4-16. Connecting Input Power

A. Connecting Three-Phase Input Power

3

4

3

6

! Installation must meet all National

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

! Disconnect and lockout/tagout in-

put power before connecting input

= GND/PE Earth Ground

conductors from unit.

! Always connect green or green/

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

. The Auto-Line circuitry in this unit au-

tomatically adapts the power source

7

2

L1

5

L2

L3

1

to the primary voltage being applied.
Check input voltage available at site.
This unit can be connected to any in­put power between 120 and 460 VAC
without removing cover to relink the
power source.

For Three-Phase Operation

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

protection using Section 4-15 (fused dis­connect switch shown).

Close and secure door on disconnect de­vice. Remove lockout/tagout device, and
place switch in the On position.

OM-2226 Page 26

Tools Needed:

2/04 - Ref. 802 136-A

B. Connecting Single-Phase Input Power

1

8

10

7

9

L1

L2

3

6

=GND/PE Earth Ground

1

1

3

6

5

! Installation must meet all National

and Local Codes − have only quali-

fied persons make this installation.

! Disconnect and lockout/tagout in-

put power before connecting input

conductors from unit.

! Always connect green or green/

yellow conductor to supply

grounding terminal first, and never

to a line terminal.

. The Auto-Line circuitry in this unit au-

tomatically adapts the power source

to the primary voltage being applied.

Check input voltage available at site.

This unit can be connected to any in-

put power between 120 and 460 VAC

without removing cover to relink the

power source.

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

2

4

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 4-15 (fused dis­connect switch shown).

Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

2/04 - Ref. 802 136-A

OM-2226 Page 27

5-1. Controls

SECTION 5 − OPERATION

1

23

6

4

8

5

. For all front panel switch pad controls: press

switch pad to turn on light and enable
function.

. Green on nameplate indicates a TIG func-

tion, Gray indicates a Stick function.

1 Encoder Control
Use encoder control in conjunction with applica-

ble front panel function switch pads to change
values for that function. See Section 5-2.

2 Ammeter And Parameter Display

9 10

See Section 5-4.
3 Voltmeter
See Section 5-5.
4 Process Controls
See Section 5-6.
5 Output Controls
See Section 5-8.
6 Amperage And Spot Time Control
For Amperage control, see Section 5-3.
For Spot Time control, see Section 5-12.

7

7 Adjust Controls
See Section 5-11.
8 Power Switch
Use switch to turn unit On/Off.
9 Pulser Controls (DX And

LX Models)
See Section 5-9.
10 Sequencer Controls (DX, LX

And All CE Models)
See Section 5-10.

OM-2226 Page 28

ST-207 690-A / ST-802 452

5-2. Encoder Control

5-3. Amperage Control

1 Encoder Control
Use control in conjunction with ap-

1

plicable front panel function switch
pad to set values for that function.

3

5-4. Ammeter And Parameter Display

1 A (Amperage Control)
2 Encoder Control
3 Ammeter

2

1

1

See Section 5-13 for Amperage
control range.

Press Amperage switch pad and
turn Encoder control to set weld
amperage. Weld amperage setting
is also peak amperage when Pulser
function is active (see Section 5-9).

1 Ammeter
Displays actual amperage while

welding. Meter also displays preset
parameters for any of the following
units of measure when they are ac­tive: amperage, time, percentage or
frequency. The corresponding
LED, located directly below the am­meter, will also illuminate.

OM-2226 Page 29

5-5. Voltmeter

5-6. Process Control

1 Volt Meter
Displays output or open circuit volt-

1

age. If output is off, the voltmeter will
display a series of three dashes
(-−−). Open circuit voltage is dis­played if power is on and output is
available.

1 Process Control
Press switch pad until desired pro-

cess LED is illuminated:
TIG HF Impulse - When selected,

a pulsed HF (non-contact) (see
Section 5-7) arc starting method is
activated. This method can be used
with either AC or DC TIG welding.
Make connections according to
Section 4-12.

1

TIG Lift-Arct - When selected, is
an arc starting method in which the
electrode must come in contact
with the workpiece to initiate an arc
(see Section 5-7). This method can
be used with either AC or DC TIG
welding. Make connections ac­cording to Section 4-12.

Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections ac­cording to Section 4-13.

OM-2226 Page 30

5-7. Lift-Arc™And HF TIG Start Procedures

Lift-Arc Start Method

1

2

“Touch”

Do NOT Strike Like A Match!

1 − 2

Seconds

Lift-Arc Start

When Lift-Arct button light is On, start arc as
follows:

1 TIG Electrode
2 Workpiece
Touch tungsten electrode to workpiece at weld start

point, enable output and shielding gas with torch
trigger, foot control, or hand control. Hold electrode
to workpiece for 1-2 seconds, and 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 or AC GTAW process
when HF Start method is not permitted, or to replace
the scratch method.

HF Start

When HF Start button light is On, start arc as
follows:

High frequency turns on to help start arc when out­put is enabled. High frequency turns off when arc is
started, and turns on whenever arc is broken to help
restart arc.

Application:

HF start is used for the DCEN GTAW process when
a non-contact arc starting method is required.

OM-2226 Page 31

5-8. Output Control

1

1 Output Control
Press switch pad until desired parameter

LED is illuminated.

RMT STD (Remote Standard)

Application: Use Remote Trigger (Stan-

dard) when the operator desires to use a
foot pedal or finger amperage control (see
Section 6-3A).

. When a foot or finger remote current

control is connected to the welding
power source, initial amps, initial
slope, final slope, and final amps are

controlled at the remote control, not at
the welding power source.

. If On/Off only type trigger is used, it

must be a maintained switch. All Se­quencer functions become active, and
must be set by the operator.

RMT 2T HOLD
Application: Use Remote Trigger Hold

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

If a foot or finger current control is con­nected to the welding power source, only

trigger input is functional (see Section
6-3B).

. This switch function can be reconfi-

gured for 4T, 4T Momentary, Mini Log­ic, or Spot control See Section 6-3)

ON

Output will energize two seconds after be­ing selected.

Application: Use Output On for Stick
(SMAW) welding, or for Lift-Arc without the
use of a remote control (see Section
6-3H).

OM-2226 Page 32

5-9. Pulser Control (DX And LX Models)

3

1

4

1 Pulser Control
Pulsing is available only while using

the TIG process, it cannot be se­lected if the Stick process (see Sec-

2

tion 5-6) is active. Controls can be ad­justed while welding.

Press switch pad to enable pulser.
ON - When illuminated, this LED in-

dicates the pulser is on.
Press switch pad until desired pa-

rameter LED is illuminated.
To turn Pulser off, press and release

switch pad until the On LED turns off.
2 Encoder Control
3 Ammeter
Turn encoder (see Section 5-2) to se-

lect appropriate value for active pulse
parameter. Value selected is shown
on the ammeter (see Section 5-4).
Also, the ammeter LED for the corre­sponding unit of measure (%, A, s,
Hz) of the active parameter will be il­luminated.

See Section 5-13 for all Pulser pa­rameter ranges.

PPS (Pulses Per Second or Pulse
Frequency) - Control is used to de­termine appearance of weld bead.

PEAK t - The percentage of each
pulse cycle that can be spent at the
peak amperage level.

Percent (%) Peak

Time Control Setting

Balanced

More Time

At Peak

Amperage

More Time

At

Background

Amperage

(50%)

(80%)

(20%)

Bkg Amp

Peak Amp

Pulsed Output Waveforms

PPS

BKGND A (Background Amps) - Use
Background Amps control to set the
low pulse of the weld amperage,
which cools the weld puddle and af­fects overall heat input. Background
Amps is set as a percentage of peak
amperage.

4 Pulsed Output Waveforms
Example shows affect changing the

Peak Time control has on the pulsed
output waveform.

. Peak amperage is set using the

Amperage control (see Section
5-3). Peak amperage is the high­est welding amperage allowed to
occur in the pulse cycle. Weld
penetration varies directly with
peak amperage.

Application:

Pulsing refers to the alternating rais­ing and lowering of the weld output at
a specific rate. The raised portions of
the weld output are controlled in
width, height, and frequency, forming
pulses of weld output. These pulses
and the lower amperage level be­tween them (called the background
amperage) alternately heat and cool
the molten weld puddle. The com­bined effect gives the operator better
control of penetration, bead width,
crowning, undercutting, and heat in­put. Controls can be adjusted while
welding.

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

OM-2226 Page 33

5-10. Sequencer Controls (DX Models Only)

3

1

1 Sequencer Control
Sequencing is available only while

using the TIG process, but is dis­abled if a remote foot or finger cur­rent control is connected to the Re­mote receptacle while in the RMT

2

4

STD mode. Sequencer parameters
cannot be selected if the Stick pro­cess (see Section 5-6) is active.

Press switch pad until desired pa­rameter LED is illuminated.

2 Encoder Control
3 Ammeter
Turn encoder (see Section 5-2) to

set appropriate value for active se­quence parameter. Value selected
is shown on the ammeter (see Sec­tion 5-4). Also, the ammeter LED for
the corresponding unit of measure
(A, S) of the active parameter will be
illuminated.

See Section 5-13 for all Sequencer
parameter ranges.

INITIAL A (Initial Amperage) - Use
control to select a starting amper­age that is different from the weld
amperage.

Application:

Initial Amperage can be used while
GTAW welding to assist in preheat­ing cold material prior to depositing
filler material, or to ensure a soft
start.

INITIAL t (Initial Time)(LX Models
Only) - Press control again and turn

Encoder to select amount of time
that is needed at the beginning of
the weld.

INITIAL SLOPE t (Initial Slope
Time) Use control to select amount
of time that it takes to slope up/
down from initial amperage to weld
amperage. To disable, set to 0.

4 Amperage Switch Pad
Weld Time (LX Models Only) -

Press Amperage switch pad twice.
Set desired length of weld time.

FINAL SLOPE t (Final Slope Time)

- Use control to select amount of
time that it takes to slope up/down
from weld amperage to final amper­age. To disable, set to 0.

Application:

Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.

FINAL A (Final Amperage) - Use
control to select amperage to which
weld amperage has sloped up/
down to.

FINAL t (Final Time)(LX Models
Only) - Press control again and turn

Encoder to select amount of time
that is needed at the end of the
weld.

OM-2226 Page 34

5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge)

3

2

1

1 Adjust
Press switch pad until desired function

LED is illuminated.
2 Encoder Control
3 Ammeter
Turn encoder (see Section 5-2) to set ap-

propriate value for active Adjust parame­ter. Value selected is shown on the am­meter (see Section 5-4). Also, the am­meter LED for the corresponding unit of
measure (S, %) of the active parameter
will be illuminated.

See Section 5-13 for all Adjust parame­ter ranges.

PREFLOW - If the TIG HF process is ac­tive (see Section 5-6) and Preflow is
shown on the control panel, use control
to set length of time gas flows before arc
initiation. To set Preflow time for models
that do not have Preflow Time control on
the front panel, see Section 6-1.

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

POST FLOW - If the TIG process is ac­tive (see Section 5-6), use control to set
length of time gas flows after welding
stops.

Application:

Postflow is required to cool tungsten and
weld, and to prevent contamination of
tungsten and weld. Increase postflow
time if tungsten or weld are dark in ap­pearance.

DIG - If the Stick process is active (see
Section 5-6), use control to set amount of
DIG. When set at 0, short-circuit amper­age at low arc voltage is the same as nor­mal welding amperage.

When setting is increased, short-circuit
amperage at low arc voltage increases.

Application:

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

PURGE - While in the TIG process (see
Section 5-6), to activate the gas valve
and start the purge function, push and
hold the Adjust switch pad for the desired
amount of purge time. To set from 0 to 50
seconds of additional purge time, contin­ue to hold the Adjust switch pad while
turning the encoder control. Factory de­fault setting is 0.

While Purge is active, [PUR] is shown in
the left display, and purge time is shown
in the right display.

Pressing any front panel switch pad will
end the purge time display, but gas will
continue to flow until the preset time has
timed out.

Application: Purge is used to clear the
shielding gas lines of contaminates.

OM-2226 Page 35

5-12. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection)

SPO

1

1.0

3

2

5-13. Factory Parameter Defaults And Range And Resolution

Parameter Default Range And Resolution

PROCESS

* Stick OCV

TIG HF Impulse

Low OCV

1 Spot Time Meter Display
Select Spot function according to

Section 6-3G.
2 Amperage Switch Pad
3 Encoder Control
Set spot parameters as follows:

Press Amperage switch pad once
(meter A LED turns on) and turn En­coder to set spot amperage. Press
Amperage switch pad again, (meter
S LED lights) and turn Encoder to
set spot time (.1−25 seconds). Fac­tory default setting is 1 second.

Application: To provide a timed
weld. Used for tacking, and thin
sheet joining.

TIG HF Impulse / TIG Lift / Stick

Low OCV / Normal OCV

*Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off)

OUTPUT

1

RMT 2T

A MAIN / PEAK

DC TIG

DC STICK

Spot Time

**Weld Time

PULSER

PPS

PEAK t

BKGND A

*Meter “PPP” Display −−− (Off) −−− (Off) / PPPP (On)

SEQUENCER

RMT STD

2T

150 A

110 A

1.0 S

0 S

Off

100 Hz

40%

25%

RMT STD / RMT 2T / ON

RMT 2T can be reconfigured for: 2T / 4T / Mini Logic
/ 4T Momentary / Spot (see Section 6-3)

1 − 200 Amps

1 − 200 Amps

0.1 − 25.0 Seconds

Dual Range And Resolution

0.0 − 99.9 / 100 − 999 Seconds

ON / OFF

Dual Range And Resolution

0.1 − 9.9 / 10 − 500 Hertz

5 − 95 Percent

5 − 95 Percent

INITIAL A

**Initial Time

INITIAL SLOPE t

FINAL SLOPE t

FINAL A

**Final Time

OM-2226 Page 36

20 A

0 S

0 S

0 S

5 A

0 S

1 − 200 Amps

0.0 − 25.0 Seconds

0.0 − 25.0 Seconds

0.0 − 25.0 Seconds

1 − 200 Amps

0.0 − 25.0 Seconds

ADJUST

*PREFLOW

POST FLOW

DIG

MAXSTAR:

*Tungsten

***Amperage

***Time

***Start Slope Time

***Preset Amperage Minimum

* Parameter adjusted using an Advanced Functions configuration only (see Section 6).

**

Parameter used with the automation option (LX models only).

***Parameter adjust using Tungsten GEN only.

0.2 S

10.0 S

30%

.094

60

1

40

3

5-14. Resetting Unit To Factory Default Settings (All Models)

0.0 − 25.0 Seconds

0.0 − 50.0 Seconds @ 0.2 Second Resolution

0 − 100 Percent

GEN, .020, .040, .062, .094, .125

1 − 200 Amps

1 − 200 Milliseconds

0 − 250 Milliseconds

1 − 20 Amps

1 Process Switch Pad
2 Output Switch Pad
3 Adjust Switch Pad
4 Power Switch
To reset all welding power source

functions to original factory settings,
lockout feature must be off (see Sec­tion 6-7). Next turn power on, then
press the Process, Output, and Ad­just switch pads before the software
version clears the meters, and hold
the switch pads until software ver­sion clears the meters.

1

2

3

Rear Panel

4

OM-2226 Page 37

5-15. Arc Timer/Counter Display

3/4

123

1

456

1

2

1 Output And Amperage Controls
2 Power Switch
To display the arc timer/counter, turn power

switch on, and then press the Amperage
Control and Output switch pads before the
software version clears the meters, and
hold the switch pads until software version
clears the meters

And

3 Arc Timer Display
Upon power up as described above, the

meter S LED will turn on, and arc time will
be displayed for 5 seconds as [000 000 ] to
[999 999]. The first four numbers indicate
hours, and the last two numbers indicate
minutes. Arc time shown in example is read
as 1,234 hours and 56 minutes. Maximum
arc time is 9,999 hours and 59 minutes.

Rear Panel

4 Arc Counter
After 5 seconds, the meter A LED turns on,

and the arc counter will be displayed for the
next 5 seconds as [000 000] to [999 999].
The maximum arc cycle count is 999 999.

OM-2226 Page 38

SECTION 6 − ADVANCED FUNCTIONS

6-1. Accessing Advanced Functions

3

1

1 Amperage Switch Pad
2 Adjust
3 Encoder Control
To access the advanced functions, press

and hold the Amperage (A) switch pad and
then press the Adjust switch pad. To scroll
through the advanced functions, press and
release the Adjust switch pad. Use the En­coder control to change parameters for
each function.

Advanced Functions:

• Programmable TIG Start Parameters
(see Section 6-2) − Allows you to set
amps, time, and polarity to customize arc

starts for different tungstens.

• Output Remote Hold And Trigger Func­tions (see Section 6-3) − For reconfigur-
ing RMT 2T Hold for 3T, 4T Momentary,
or Mini Logic

• Preflow Time (see Section 6-4) − Sets the
gas flow time before TIG arc starts.

• Stick OCV Selection (see Section 6-5) −
Allows you to select either low or normal
OCV (open circuit voltage).

• Stick Stuck Check Selection (See Sec­tion 6-6) − With Stick Stuck Check on and
the welding electrode (rod) stuck, output

2

is turned off in an attempt to save the rod
for reuse.

• Lockout Functions (see Section 6-7) −
Allows you to turn the lockout function on
and off and adjust the lockout levels.

• Meter Displays (see Section 6-8) − Al-
lows you to set meters to display weld
voltage and amperage, or blank meters
while pulse welding.

• External Pulse Control (see Section 6-9)

− Used for external pulse control when
external pulse control is desired.

To exit advanced functions, press and hold
the Amperage (A) switch pad and then
press the Adjust switch pad.

OM-2226 Page 39

6-2. Programmable TIG Start Parameters

A. Tungsten Selection

3

2

Current (A)

Start Time

tun

Start Amperage

Start Slope
Time

094

1

Preset Amperage Minimum

1 Amperage Switch Pad
2 Encoder Control
3 Amps Meter

OM-2226 Page 40

Preset TIG Start Parameters

Use Encoder control to select a tungsten
size from the following: .020, .040, .062
(1/16 in.), .094 (3/32 in.), or .125 (1/8 in.)
(.094 is the default). When one of the listed
tungsten sizes is selected, the following
TIG starting parameters are preset: Am-

perage, Start Time, Start Slope Time, and
Preset Amperage Minimum. If it is neces­sary or desired to manually set the TIG
starting parameters, turn the encoder until
[GEn] is displayed on the amps meter (see
Section B).

B. Selecting GEN

GEn

1 Encoder Control

2

1

3

2 Amps Meter
3 Amperage Switch Pad
If [GEn] is selected and displayed

on the amps meter, the TIG starting
parameters for a .094 tungsten are
the default: Start Amperage = 60 A,
Start Time = 1 ms, Start Slope Time
= 40 ms, Preset Minimum Amps =
3 A. These parameters can be
manually changed by pressing the
Amperage switch pad to step
through each adjustable paramet­er. To change parameters, see Sec­tions C, D, E, and F.

Current (A)

Start Time

GEN Default DC TIG Start Parameter Relationships

Start Amperage

60 Amps

Preset Amperage Minimum

3 Amps

1 ms

Start Slope Time

40 ms

OM-2226 Page 41

C. Changing Programmable TIG Start Amperage

3

2

Current (A)

Start
Amperage

1 Amperage Switch Pad

2 Encoder Control

3 Amps Meter

StA

20

To adjust TIG Start Amperage proceed as
follows:

Press Amperage switch pad. Switch pad
LED turns on, and meter A LED turns on.
The current Start Amperage is displayed on

1

the amps meter, and can be adjusted (see
Section 5-13) by turning the Encoder con­trol.

To change Start Time, proceed to Section
D.

D. Changing Programmable Start Time

Stt

Current (A)

Start Time

1 Amperage Switch Pad
2 Encoder Control
3 Amps Meter
To adjust Programmable Start Time pro-

ceed as follows:
Press Amperage switch pad, and meter S

LED turns on. The current Start Time is dis­played in milliseconds on the amps meter,

3

2

10

1

and can be adjusted by turning the Encoder
control (see Section 5-13).

To change Start Slope Time, proceed to
Section E.

OM-2226 Page 42

E. Changing Start Slope Time

3

2

StS

Current (A)

Start Slope Time

1 Amperage Switch Pad

2 Encoder Control

3 Amps Meter

20

To adjust Start Slope Time proceed as fol­lows:

Press Amperage switch pad. Switch pad
LED turns on, and meter S LED turns on.
The Start Slope Time is displayed in milli-

F. Changing Preset Amperage Minimum

1

seconds on the amps meter, and can be ad­justed (see Section 5-13) by turning the
Encoder control.

To change Preset Amperage Minimum,
proceed to Section F.

PA_

Current (A)

1 Amperage Switch Pad
2 Encoder Control
3 Amps Meter
To adjust Preset Amperage Minimum pro-

ceed as follows:

3

5

Preset Amperage Minimum

Press Amperage switch pad. Switch pad
LED turns on, and meter A LED turns on.
The Preset Minimum Amperage is dis­played on the amps meter, and can be ad­justed (see Section 5-13) by turning the
Encoder control.

2

1

. Whatever amperage is selected as the

preset amperage minimum, is the min­imum amperage that the machine will
provide.

OM-2226 Page 43

6-3. Output Control And Trigger Functions

A. Remote (Standard) Torch Trigger Operation

Current (A)

Main Amps

Initial Slope

Initial Amps

Preflow

P & H

Maintained Switch Foot Or Finger

P&H = Push trigger and hold
R = Release trigger.

R

Final Slope

Final Amps

Postflow

R

Remote Control

. When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope and final

amps are controlled by the remote control, not by the welding power source.

B. Remote 2T Torch Trigger Operation

Current (A)

Main Amps

Initial Slope

Initial Amps

Preflow

P&R

P&R = Push trigger and release.

P&R

. If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.

Final Slope

Final Amps

Postflow

OM-2226 Page 44

C. 3T Specific Trigger Method

1

rt

Current (A)

Remote Trigger Operation

*

*

*

A B CD

Preflow

Initial Amps/Initial Slope Main Amps Final Slope /Final Amps Postflow

3t

*

*

*

2

=3T

*

E

* Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc.

1 3T (Specific Trigger Operation)
Sequencer is required to reconfigure for 3T.

3T requires a specific type of remote con­trol with two independent momentary­contact switches. One will be designated

initial switch, and it must be connected be­tween Remote 14 receptacle pins A and B.
The second will be designated as the final
switch, and it must be connected between
Remote 14 receptacle pins D and E.

2 Encoder Control
To select 3T, turn Encoder control.

Definitions:
Initial slope rate is the rate of amperage

change determined by the initial amperage,
initial slope time, and main amperage.

Final slope rate is the rate of amperage
change determined by the main amperage, fi­nal slope time, and final amperage.

Operation:
A. Press and release initial switch within 3/4

second to start shielding gas flow. To stop
the preflow sequence before preflow time
elapses (25 seconds), press and release
final switch. The preflow timer will reset
and the weld sequence can be started
again.

. If an initial switch closure is not made

again before preflow time ends, gas flow
stops, the timer resets, and an initial
switch press and release is necessary to
start the weld sequence again.

B. Press initial switch to start arc at initial

amps. Holding switch will change amper­age at initial slope rate (release switch to
weld at desired amperage level).

C. When main amperage level is reached,

initial switch can be released.

D. Press and hold the final switch to de-

crease amperage at final slope rate (re­lease switch to weld at desired amperage
level).

E. When final amperage has been reached,

the arc extinguishes and shielding gas
flows for the time set on the Postflow con­trol.

Application:

With the use of two remote switches instead
of potentiometers, 3T gives the operator the
ability to infinitely increase, decrease, or
pause and hold amperage within the range
determined by the initial, main, and final am­perages.

OM-2226 Page 45

D. 4T Specific Trigger Method

2

=

4T

1 4T (Specific Trigger Operation)
2 Encoder Control
To select 4T, turn Encoder control.

Torch trigger operation is as shown.
4T allows the operator to toggle between weld current and final

current.

rt

1

4t

. When a remote switch is connected to the welding power

source, use the remote switch to control the weld cycle.
Amperage is controlled by the welding power source.

Current (A)

Torch Trigger Operation

Main Amps

Initial Slope

Initial Amps

Preflow

P/H R

P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds

P/R

P/R

P/H R

Application:

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

Final Slope

Final Amps

Postflow

E. Mini Logic Operation

rt

Initial Amps

Preflow

4tL

Initial Slope

*

1

Torch Trigger Operation

Main Amps

*

*

2

=

Mini Logic

1 Mini Logic Meter Display
2 Encoder Control
To select Mini Logic, turn Encoder control.

Torch trigger operation is as shown.
Mini logic allows the operator to toggle between initial slope

or main amps and initial amps. Final Amperage is not avail­able. Final slope will always slope to minimum amperage
and end the cycle.

. When a remote switch is connected to the welding pow-

er source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power
source.

Application: This ability to change current levels without ei­ther initial slope or final slope, gives the operator the opportu­nity to adjust filler metal without breaking the arc.

Final Slope

*

Postflow

P/H R

P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
* = Arc can be extinguished at final slope rate at any time by pushing and holding trigger

OM-2226 Page 46

P/R P/R P/R

P/R P/R P/H

F. 4T Momentary Operation

1 4T Momentary Meter Display
2 Encoder Control
To select 4T Momentary, turn Encoder control.

4T Momentary torch trigger operation is as shown.

. When a remote switch is connected to the welding pow-

er source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power
source.

Application:

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

rt

Current (A)

Preflow

4tE

Initial Slope

Initial Amps

1

2

= 4T Momentary Main

Main Amps

Final Slope

Final Amps

*

Postflow

P/R

P/R = Push and release trigger; * = Push and releasing during final slope will break the arc and go to postflow

P/R P/R

. For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends.

P/R

P/R

OM-2226 Page 47

G. Spot Control Operation

1 Spot Function Meter Display

. While in Spot Control, Se-

quencer settings will be ig­nored and will not be program­mable.

. When a remote switch is con-

nected to the welding power
source, use the remote switch
to control the weld cycle. Am­perage is controlled by the
welding power source.

Torch trigger operation is as shown.
Application: To provide a timed

1

weld. Used for tacking, and thin
sheet joining.

Current (A)

Preflow

rt

SPO

Timed Spot Weld Amps

=

Spot

Postflow

Push & Hold
Trigger

OM-2226 Page 48

Release Trigger After
Spot Time Is Done

H. On Trigger Operation

Voltage (V)

2 Sec

ON

Current (A)

Current (A)

Touch Stick

Electrode

Touch Current

Initial Amperage

Stick

Lift

Initial Slope

Main Amperage

Lift Stick

Electrode

Touch Tungsten

Lift Tungsten
Slightly

Lift Tungsten

OM-2226 Page 49

6-4. Setting Preflow Time

PrE

0.2

6-5. Stick Open-Circuit Voltage (OCV) Selection

1 Encoder Control

1

Turn encoder to select from 0 to
25 seconds of preflow. The value
selected is displayed on the am­meter.

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

oc

1 Encoder Control
2 Meter Display
Turn Encoder to change between low OCV

and normal OCV. Active selection is dis-

6-6. Stick Stuck Check Selection

played on the meters.
When Stick low OCV is selected, open-cir-

cuit voltage is between 9 and 14 volts.
When Stick normal OCV is selected, open­circuit voltage is approximately 72 volts.

LO

2

Application: For most Stick applications
use low open-circuit voltage. Use normal
open-circuit voltage for hard to start Stick
electrodes, or if required for your particular
application.

2

1

1

1 Encoder Control
2 Ammeter Parameters Select Display
Turn Encoder to change between Stick

Stuck Check [ON and [OFF] meter display.
When Stick Stuck Check is on and the

welding electrode (rod) is stuck, output is
turned off.

OM-2226 Page 50

Stc

Application: For most Stick applications,
use Stick Stuck Check off. With Stick
Stuck Check on and the welding electrode
(rod) stuck, output is turned off in an at­tempt to save the rod for reuse. This allows
the operator time to un-stick the rod, or dis­connect the rod holder from the rod without
arc occurring. Turn Stick Stuck Check on

ON

when this function is desired.

. Some applications may require Stick

Stuck Check to be turned off. For ex­ample: Large stick electrodes operat­ing at high amperages would require
Stick Stuck Check to be turned off.

6-7. Lockout Functions

A. Accessing Lockout Capability

1

2

Loc

Toggle

Toggle

oFF

Select Lockout Level

1, 2, 3, or 4

cod

See Section 5 for explanation of controls referred to in all of
Section 6-7.

There are four (1−4) different lockout levels. Each successive level
allows the operator more flexibility.

. Before activating lockout levels, be sure that all procedures and

parameters are established. Parameter adjustment is limited
while lockout levels are active.

To turn On the lockout feature, proceed as follows:

1 Encoder Control
2 Amperage (A) Switch Pad
Press Amperage (A) switch pad to toggle between the lock and code

displays. Toggle switch pad until code is displayed.
Turn Encoder control to select a lockout code number. The code

number will appear on the amp meter. Select any number from [1]

oFF

thru [999]. IMPORTANT: remember this code number, as you will
need it to turn the lockout feature off.

Toggle Amperage (A) switch pad until lock is displayed. You may now
select a lockout level.

There are four lockout levels available. Turn Encoder control to se­lect a lockout level (see Sections 6-7B for lockout level descriptions).

Once the desired three digits have been entered and a lockout level
selected, exit advanced functions mode (see Section 6).

To turn Off the lockout feature, proceed as follows:

Use Encoder control to enter the same code number that was used
to turn on the lockout feature.

Press the Amperage (A) switch pad. The amperage (right) meter dis­play will change to [OFF]. The lockout feature is now off.

Select Code Number

1 to 999

OM-2226 Page 51

B. Lockout Levels

L2 L1 L3

Levels 1, 2, And 3

Use Encoder Control To Adjust
Amperage ±10% Of Preset

L3

Value.

Indicates which functions are available
for the corresponding lockout level.

AJ

K

B

L

C

D

I

NH

M

G

F

E

. Before activating lockout levels, be

sure that all procedures and parame­ters are established. Parameter adjust­ment is limited while lockout levels are
active.

Level 1

. Remote amperage control is not avail-

able in level 1.

TIG Output Selection

If either the TIG HF Impulse or TIG Lift Arc
process (see Section 5-6) was active when
lockout level 1 was activated, the operator
can choose between RMT STD (Remote
Standard) or RMT 2T HOLD (Remote 2T
Hold) (see Section 5-8). The On function is
also available if TIG Lift Arc was active.

Stick Output Selection

If the Stick process was active when lock­out level 1 was activated, the operator can
choose between RMT STD or On.

When parameter change or selection is lim-

Level 4

ited by lock level 1, [LOCK][LEV1] is dis­played as a reminder.

Level 2

. Remote amperage control is not avail-

able in level 2.

Includes all the functions of level 1 plus Pro­cess Selection (see Section 5-6).

When parameter change or selection is lim­ited by lock level 2, [LOCK][LEV2] is dis­played as a reminder.

Level 3

. Remote amperage control is not avail-

able in level 3.

Includes all the functions of levels 1 and 2
plus the following:

+10% adjustment of preset TIG or Stick
Weld Amps

Select desired process, TIG or Stick, and
use Encoder control to adjust amperage +/−
10% of preset amperage value, up to the

limits of the machine. If operator tries to go
beyond the ±10%, the amperage (right) me­ter will display [LOCK][LEV3] as a reminder.

Pulser ON/Off Control

Gives operator the ability to turn on/off the
Pulser control.

When parameter change or selection is lim­ited by lock level 3, [LOCK][LEV3] is dis­played as a reminder.

Level 4

Includes all the functions of levels 1, 2, and
3 plus the following:

Remote Amperage Control

Allows operator to use remote amperage
control if desired. Remote control operates
from minimum to maximum of preset am­perage value. Connect remote control de­vice according to Section 4-8.

When parameter change or selection is lim­ited by lock level 4, [LOCK][LEV4] is dis­played as a reminder.

OM-2226 Page 52

6-8. Setting Unit To Display PPP While Pulse Welding (DX Models Only)

PPP

PLS

6-9. External Pulse Control

− − −

2

1

1 Encoder Control
2 PPP Meter Display
Turn Encoder to change between

standard and [PPP] meter
display.

When the [PPP] meter display
feature is active while pulse weld­ing, the [PPP] will be displayed on
the right meter display, and the
Meter Hold feature is disabled.

The [PPP] meter display feature
will not effect the normal amper­age display or Meter Hold capabil­ities when in a non-pulse welding
mode.

EPc

oFF

1 Encoder Control
2 Ammeter Parameter Selec-

tion

Turn Encoder to select external
pulse control on or off (off is the
default).

When external pulse control is on:

2

1

Remote 14-pin amperage control
of 0 to 10 volts input will be a min­imum 0 amps to the power
source, a maximum 200 amps
with an external direct amperage
control to power source.

OM-2226 Page 53

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power before maintaining.

. Maintain more often during severe conditions.

A. Welding Power Source

n = Check Z = Change ~ = Clean Δ = Repair l = Replace
* To be done by Factory Authorized Service Agent

Every
3
Months

nl Labels n l Gas Hoses

Every
3
Months

nΔ lCables And Cords

Every
6
Months

! Do not remove case when

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

~:Durning heavy service, clean monthly.

B. Optional Cooler

n = Check Z = Change ~ = Clean Δ = Repair l = Replace
* To be done by Factory Authorized Service Agent

Every
3
Months

Every
6
Months

~Coolant Strainer,
durning heavy service,
clean more frequently.

~ Blow out heat exchanger fins.

nCheck coolant level. Top off with

distilled or deionized water if necessary.

nlHoses

Every
12
Months

ZReplace coolant.

OM-2226 Page 54

nl Labels

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.

ST-802 451

OM-2226 Page 55

7-3. Voltmeter/Ammeter Help Displays

0

V

HEL P-0

1

HEL P-1

2

HEL

3

HEL P-3

4

HEL P-4

A

AV

AV

P-2

AV

AV

6

AV

HEL P-8

AV

7

HEL P-9

AV

8

HEL P10

AV

9

HEL P12

AV

10

HEL P13

5

HEL P-5

. All directions are in reference to the

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

0 Help 0 Display

Indicates a short in the thermal protection
circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this display is shown.

1 Help 1 Display

Indicates a malfunction in the primary pow­er circuit caused by an overcurrent condi­tion in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this display is shown.

2 Help 2 Display

Indicates an open in the thermal protection
circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this display is shown.

AV

3 Help 3 Display
Indicates the bottom heat sink has over-

heated. The unit has shut down to allow the
fan to cool it (see Section 4-5). Operation
will continue when the unit has cooled.

4 Help 4 Display
Indicates an open in the thermal protection

circuitry located on the top heat sink. Con­tact a Factory Authorized Service Agent if
this display is shown.

5 Help 5 Display
Indicates the top heat sink has overheated.

The unit has shut down to allow the fan to
cool it (see Section 4-5). Operation will con­tinue when the unit has cooled.

6 Help 8 Display
Indicates a malfunction in the secondary

power circuit of the unit. There is a high
open circuit condition. Contact a Factory
Authorized Service Agent if this display is
shown.

11

AV

HEL P21

7 Help 9 Display
Indicates a short in the thermal protection

circuitry located on the top heat sink. Con­tact a Factory Authorized Service Agent if
this display is shown.

8 Help 10 Display
Indicates torch trigger is depressed. Re-

lease trigger to continue.
9 Help 12 Display
Indicates an improper set-up. You are trying

to make an adjustment that is not allowed.
10 Help 13 Display (LX Models Only)
Output enable signal broken causing weld

output to stop, but gas continues to flow if
Post Flow function is active or gas control
on 10-pin is On (see Section 4-9).

11 Help Display 21
Indicates voltage or current feedback has

been detected with contactor off. Contact a
Factory Authorized Service Agent if this
display is shown.

OM-2226 Page 56

7-4. Troubleshooting

Trouble Remedy

No weld output; unit completely
inoperative.

Place line disconnect switch in On position (see Section 4-16).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-16).

Check for proper input power connections (see Section 4-16).

No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14

Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-7).

Fan not operating. Check for and remove anything blocking fan movement.

Wandering arc

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

receptacle (see Section 4-8 as applicable).

Input voltage outside acceptable range of variation (see Section 4-15).

Check, repair, or replace remote control.

Unit overheated. Allow unit to cool with fan On (see Section 4-5).

Clean and tighten all weld connections (see Section 4-7).

Have Factory Authorized Service Agent check fan motor.

Use proper size tungsten (see Section 11).

Use properly prepared tungsten (see Section 11).

Reduce gas flow rate (see Section 4-11).

Shield weld zone from drafts.

Increase postflow time (see Section 5-1).

Check and tighten all gas fittings (see Section 4-11).

Water in torch. Refer to torch manual.

OM-2226 Page 57

Notes

OM-2226 Page 58

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

SECTION 8 − ELECTRICAL DIAGRAMS

Figure 8-1. Circuit Diagram

237 566-B

OM-2226 Page 59

SECTION 9 − HIGH FREQUENCY (HF)

9-1. Welding Processes Requiring High Frequency

1

Work

TIG

9-2. Correct Installation

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

between torch and workpiece and/
or stabilize the arc.

5

7

50 ft

(15 m)

Ground All

Metal Objects

And All Wiring
In Welding Zone
Using #12 AWG

Wire

Nonmetal

Building

1

Weld Zone

3

Ground

Workpiece

If Required

By Codes

6

50 ft

(15 m)

4

2

7

8

7

7

1 HF Source (Welder With Built-In HF Or

Separate HF Unit)

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

2 Welding Zone And Centerpoint
A circle 50 ft (15 m) from centerpoint

between HF source and welding torch in all
directions.

3 Weld Output Cables
Keep cables short and close together.
4 Conduit Joint Bonding And Grounding

OM-2226 Page 60

10

Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).

5 Water Pipes And Fixtures
Ground water pipes every 50 ft (15 m).
6 External Power Or Telephone Lines
Locate HF source at least 50 ft (15 m) away

from power and phone lines.
7 Grounding Rod
Consult the National Electrical Code for

specifications.

Metal Building

9

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

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

9 Windows And Doorways
Cover all windows and doorways with

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

10 Overhead Door Track
Ground the track.

SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING

10-1. DC - GTAW 16 Gauge Stainless Steel Set-Up

Ammeter

This symbol indicates which functions should be active for stainless steel.

Encoder

207 690-A

• Turn power on (switch located on rear panel)

• Press Process switch pad until TIG HF Impulse LED is lit

• Press Output switch pad until RMT STD LED is lit

• Press Adjust switch pad until Post Flow LED is lit

• Turn Encoder control to set 8 seconds of Post Flow time

• Press Amperage A switch pad until LED is lit

• Turn Encoder control to set desired amperage (50 - 80 amps).

. The ammeter displays the parameter for any of the following units of measure when they are active: amperage, time, percentage,

or frequency. The corresponding LED, located directly below the ammeter, will also light up. The ammeter also displays actual
amperage while welding.

OM-2226 Page 61

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2010-04

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

11-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens

.010 in. (1 mm) Up to 25 Up to 20
.020 in. (1 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)

11-2. 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

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.

OM-2226 Page 62

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)

12-1. 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 11.

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-2226 Page 63

12-2. 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.

12-3. 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-2226 Page 64

SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING

13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

1 Front Panel
Correct front panel display for basic

1

Stick DCEP welding.

. For all front panel switch pad

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

. Gray on nameplate indicates a

Stick function (see Section 5-1
for description of controls).

ST-207 690-A

OM-2226 Page 65

SECTION 14 − STICK WELDING (SMAW) GUIDELINES

14-1. Stick Welding Procedure

! Weld current starts when

electrode touches work-

Tools Needed:

Equipment Needed:

Constant Current

Welding Power Source

5

4

2

3

piece.

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.

. Always wear appropriate per-

sonal protective clothing.

1 Workpiece
Make sure workpiece is clean be-

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

quires less current than a large
one. Follow electrode manufactur­er’s instructions when setting weld
amperage (see Section 14-2).

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

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

7 Slag
Use a chipping hammer and wire

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

1

7

OM-2226 Page 66

6

stick 2010−02 − 151 593

14-2. Electrode and Amperage Selection Chart

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

RANGE

AMPERAGE

50

100

150

200

250

300

350

400

450

ELECTRODE

6010
6011
6013

7014

7018

7024

NI-CL

308L

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

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

DC*

AC

ALL
ALL
ALL

ALL

ALL

FLAT

HORIZ

FILLET

ALL
ALL

POSITION

DEEP
DEEP

LOW

MED

MED

LOW

LOW
LOW

PENETRATION

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

USAGE

Ref. S-087 985-A

14-3. Striking an Arc

1 Electrode
2 Workpiece
3 Arc

Scratch Technique

1

Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out, electrode was lifted too
high. If electrode sticks to work-

2

piece, use a quick twist to free it.

Tapping Technique

Bring electrode straight down to

3

1

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

2

3

S-0049 / S-0050

OM-2226 Page 67

14-4. Positioning Electrode Holder

1

1 End View Of Work Angle
2 Side View Of Electrode

Angle

10°-30°

90° 90°

Groove Welds

1

45°

45°

Fillet Welds

14-5. Poor Weld Bead Characteristics

10°-30°

2

2

2

S-0060

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

4

3

1

14-6. Good Weld Bead Characteristics

1

OM-2226 Page 68

5

S-0053-A

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding

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

5234

4 No Overlap
5 Good Penetration into Base

Metal

S-0052-B

14-7. Conditions That Affect Weld Bead Shape

Correct Angle

Angle Too Small

Electrode Angle

Arc Length

Too Short

Travel Speed

Slow

10° - 30°

Drag

Normal Too Long

Normal Fast

. Weld bead shape is affected

by electrode angle, arc
length, travel speed, and
thickness of base metal.

Angle Too Large

Spatter

S-0061

14-8. Electrode Movement During Welding

1

3

. Normally, a single stringer

bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple

2

stringer beads work better.

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side to Side

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

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

S-0054-A

OM-2226 Page 69

14-9. Groove (Butt) Joints

1

3

1/16 in.

(1.6 mm)

30°

1 Tack Welds
Prevent edges of joint from draw-

ing together ahead of electrode by
tack welding the materials in posi­tion before final weld.

2

4

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

mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 − 3/4 in.

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

Create 30 degree angle of bevel
on materials in V-groove welding.

4 Double V-Groove Weld
Good for materials thicker than

3/16 in. (5 mm).

S-0062

14-10. Lap Joint

2

14-11. Tee Joint

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.

30°
Or Less

1

3

1

45°

Or

2

Less

2

30°
Or Less

1

3

3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-

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

1 Electrode
2 Fillet Weld
Keep arc short and move at defi-

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

For maximum strength weld both
sides of upright section.

1

3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in
Section 14-8. Remove slag before
making another weld pass.

S-0063 / S-0064

OM-2226 Page 70

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

14-12. Weld Test

3

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

14-13. Troubleshooting

1 Vise
2 Weld Joint
3 Hammer
Strike weld joint in direction

shown. A good weld bends over
but does not break.

3

2 To 3 in.

(51-76 mm)

2
1

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

2

1

S-0057-B

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

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

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

welding.

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

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding

weld bead.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

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

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

welding.

OM-2226 Page 71

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

Lack of Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Excessive Penetration

Possible Causes Corrective Actions

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

Good Penetration

Reduce travel speed.

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

Good Penetration

Increase and/or maintain steady travel speed.

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

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

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

Make tack welds along joint before starting welding operation.

OM-2226 Page 72

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

Notes

OM-2226 Page 73

28

25

12

SECTION 15 − PARTS LIST

. Hardware is common and

not available unless listed.

615

13

17

614

15

38

28

11

16

400

18

401

402

19

14

33

3

35

8

6

10

2

37

30

4

1

600

OM-2226 Page 74

36

5

Figure 15-1. Main Assembly

9

7

403

803 227-G

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-1. Main Assembly

1 Fig15-2 Panel, Front W/Cmpnt 1.................. .... ..........................................

2 Fig15-3 Panel, Rear W/Cmpnt 1.................. .... ..........................................

3 Fig15-4 Magnetics Subassembly 1.................. .... ........................................

4 Fig15-5 Windtunnel, W/Components 1.................. .... .....................................

5 Fig15-7 Base Assy, 1.................. .... ...................................................

6 S1 231191 Switch, Tgl 3pst 50a 600vac Scr Term Wide Tgl 1........ ...... .... ....................

7 200393 Insulator, filter board (CE models) 1.................. .... .................................

8 PM1 204821 Kit, Input/Pre-Regulator Inverter 1....... ...... .... ..................................

9 049611 Tubing, Cop .540 Od X .123 Wall X .687 1.................. .... ..........................

10 196727 Cable, Power 10 Ft 12ga 4c Blk/Red/Wht/Grnyel 1................. .... ...................

11 +195643 Wrapper, 1................ .... .....................................................

12 206108 Handle, Rubberized Carrying 1................. .... ....................................

13 195663 Strap, Shoulder 6 Ft 1................. .... ............................................

14 189782 Insulator, Interconnect Board 1................. .... ....................................

15 C7,C8 213974 Capacitor Assy, 1..... ..... .... ...............................................

16 189778 Plug W/Leads, Vfb 1................. .... .............................................

17 231376 Plug W/Leads, Arc Starter 1................. .... .......................................

18 189768 Plug W/Leads, Gas 1................. .... .............................................

19 189779 Cable, Lem W/Plugs 1................. .... ............................................

25 189784 Insulator, wrapper 2................. .... .............................................

28 203990 Label, Warning General Precautionary (Non CE Models) 2................. .... ............

28 179310 Label, Warning General Precautionary (CE Models) 2................. .... .................

30 185835 Label, Warning Electric Shock/Exploding Parts (Non CE Models) 1................. .... .....

30 185836 Label, Warning Electric Shock/Exploding Parts (CE Models) 1................. .... .........

33 215002 Clip, Support PC Mtg 2................. .... ...........................................

35 C10 213912 Capacitor, Polye Film .1 UF 1000 VDC w/Terms (CE Models) 1...... ...... .... .........

36 L4 241027 Core, Toroidal .748 ID X 1.142 OD X .600 Thk (CE Models) 1....... ...... .... ..........

37 L5 237542 Core, Toroidal .540 ID X .875 OD X .500 THhk (CE Models) 1....... ...... .... ..........

38 235497 Plug, w/Leads 1................. .... ..................................................

400 PC2 207818 Circuit Card Assy, Power 1..... ...... .... ........................................

400 PC2 230183 Circuit Card Assy, Power (CE Models) 1..... ...... .... ............................

401 PC1 237558 Circuit Card Assy, Inverter 1..... ...... .... ......................................

401 PC1 237562 Circuit Card Assy, Inverter (CE Models) 1..... ...... .... ...........................

402 PC10 235406 Circuit Card Assy, Boost 1.... ..... .... ........................................

402 PC10 235410 Circuit Card Assy, Boost (CE Models) 1.... ..... .... .............................

403 PC 9 230203 Circuit Card Assy, Filter (CE Models) 1..... ..... .... .............................

600 229333 Screw, M10−1.5X 20 Hex Hd−pln 8.8 Pld Sems 2................ .... ....................

614 136343 Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming 2................ .... .............

615 229334 Screw, M 5− .8X 35 Pan Hd−phl Stl Pld Sems 4................ .... ......................

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

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

OM-2226 Page 75

. Hardware is common and

not available unless listed.

400

604

1

3

4

5

6

17

14

13

12

2

602

9

15

11

16

8

805 151-C

7

603

Figure 15-2. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

15-2. Panel, Front w/Components (Figure 15-1 Item 1)

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

2 195647 Panel, Front Lower 1.................. .... .............................................

3 244024 Membrane, Switch Control Maxstar 200 SD 1.................. .... ........................

3 244025 Membrane, Switch Control Maxstar 200 DX & LX 1.................. .... ...................

4 230052 Knob, .840 Dia X 6mm ID W/Spring Clip−4.5 mm Flat 1.................. .... ..............

5 194243 Door, 1.................. .... ........................................................

6 199008 Label, Door Maxstar 200 SD 1.................. .... .....................................

6 199009 Label, Door Maxstar 200 DX 1.................. .... .....................................

6 199010 Label, Door Maxstar 200 LX 1.................. .... .....................................

7 RC1 189771 Receptacle W/Leads & Plug (14 Pin) 1....... ...... .... .............................

8 202553 Rcpt, Tw Lk Insul Fem(Dinse Type)50/70 Series Wsl 2.................. .... ................

9 193649 Ftg, Gas Barbed 1/4 TBG 5/8−18 Female (Non CE Models) 1.................. .... .........

9 193650 Ftg, Gas Barbed 1/4 TBG 3/8−19 BSPP Male (CE Models) 1.................. .... ..........

11 185712 Insulator, Bulkhead Front 2................. .... ........................................

12 185713 Insulator, Bulkhead Rear 2................. .... .........................................

13 229338 Washer, Domed Load .812 ID X 1.450 OD X .070 THK 2................. .... ..............

14 185717 Nut, M20 X 1.5 1.0625 Hex .19 H Locking 2................. .... ..........................

15 185718 O-Ring 0.989 I.D. X 0.070 Wall 2................. .... ...................................

16 186228 O-Ring 0.739 I.D. X 0.070 Wall 2................. .... ...................................

17 235427 Bushing, Flg M7x.75x.68, 1/2 Inch Hex 1................. .... ............................

400 PC3 242271 Circuit Card Assy, Control & Interface w/program 1..... ...... .... ...................

602 166560 Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed (Non CE Models) 1................ ....

603 178548 Terminal, Connector Friction 1................ .... .....................................

604 098691 Stand−off, No 6−32 X .500 Lg .250 Hex Stl M&F 4................ .... ...................

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-2226 Page 76

. Hardware is common and

not available unless listed.

Figure 15-3.Panel, Rear w/Components

Ref. 199 492-C

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-3. Panel, Rear w/Components (Figure 15-1 Item 2)

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

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

3 195646 Panel, Rear Upper (SD & DX Models) 1.................. .... ............................

3 197127 Panel, Rear Upper 10-pin (LX Models) 1.................. .... ............................

4 201155 Bushing, Strain Relief .450/ .709 ID X1.608 Mtg Hol 1.................. .... .................

5 193649 Ftg, Gas Barbed 1/4 TBG 5/8−18 Female 1.................. .... .........................

5 193650 Ftg, Gas Barbed 1/4 TBG 3/8−19 BSPP Male (CE Models) 1.................. .... .........

6 RC2 199882 Receptacle, W/Leads 4 Plug 10-pin (LX Models) 1....... ...... .... ....................

146 212 Conn, Circ Ms/Met 10Pin Sz 18 Plug Cable Solder................... ....

(Mates With RC2) (LX Models) 1................................ ...................................

200 544 Conn, Circ 97/Met Clamp Str Size 18 (Mates With RC2) (LX Models) 1................... .... .

600 198245 Nut, Conduit .750 Npt Pld 1.388 Od X .150 Thk 1................ .... ....................

601 166560 Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed 1................ .... ...............

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

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

OM-2226 Page 77

. Hardware is common and

not available unless listed.

805 153-A

Figure 15-4. Magnetics Assembly w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-4. Magnetics Assembly w/Components
(Figure 15-1 Item 3)

1 195649 Panel, Plenum 1.................. .... .................................................

2 231378 Insulator 1.................. .... ......................................................

3 FM1 239380 Fan, Muffin 24vdc 3200 RPM 141 CFM 4.125 Mtg Holes 1....... ...... .... ..........

4 GS1 238805 Valve, 24VDC 2way 125 P.S.I.Custom Port .054 Orf W/Frict 1....... ...... .... ........

5 210610 Hose, Nprn Brd No 1 X .250 Id X 12.250 2.................. .... ..........................

6 CR1 198549 Relay, Encl 24vdc Spst 35a/300vac 4pin Flange Mtg 1....... ...... .... ................

7 112863 Ftg, Hose Brs Barbed M 1/4 Tbg X 5/8−18 Sae Flare 1.................. .... ...............

8 Z1 189790 Inductor, Output 1........ ...... .... ...............................................

9 L2 210599 Coil, inductor 9T 1........ ...... .... ...............................................

10 L3 206020 Coil, inductor 14T 1....... ...... .... ..............................................

11 T1 212268 Xfmr, HF Litz/Litz w/Boost 1....... ...... .... .......................................

12 109056 Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide 2................. .... .................

13 196512 Bracket, Inductor Mounting 2................. .... ......................................

14 196514 Gasket, Inductor Mounting 2................. .... ......................................

15 200385 Bracket, Mtg HF 1................. .... ...............................................

17 231208 Connector, Faston 1/4 Ring W/75 deg Bend 1................. .... .......................

22 T2 233190 Coil, XFMR Coupling 1....... ...... .... ...........................................

400 PC7 212890 Circuit Card Assy, Arc Starter 1..... ...... .... ...................................

400 PC7 228593 Circuit Card Assy, Arc Starter (CE Models) 1..... ...... .... ........................

OM-2226 Page 78

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-4. Magnetics Assembly w/Components
(Figure 15-1 Item 3) (Continued)

600 199538 Grommet, Scr No 8/10 Panel Hole .281 Sq .250 High 4................ .... ...............

603 057357 Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole 2................ .... ....................

609 137761 Nut, 750NPT 1.31Hex .27h Nyl Blk 1................ .... ..............................

611 231179 Screw, K50 x 20 Pan Hd−phl Stl Pld Pt Thread Forming 2................ .... .............

614 010381 Connector, Rectifier 1................ .... ............................................

617 170647 Bushing, Snap−in Nyl 1.312 ID X 1.500 Mtg Hole 2................ .... ...................

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-2226 Page 79

1

2

8

. Hardware is common and

not available unless listed.

4

602

6

7

3

5

Ref. 199 494-F

Figure 15-5. Windtunnel w/Components

10

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-5. Windtunnel w/Components
(Figure 15-1 Item 4)

1 195645 Bracket, Heatsink Rear 1.................. .... .........................................

2 198634 Bracket, Front Heatsink Mtg 1.................. .... .....................................

3 198633 Wind Tunnel 1.................. .... ...................................................

4 232856 Rail, Heat Sink 2.................. ...... ..............................................

5 198652 Bracket, Windtunnel Insulator 2.................. .... ....................................

6 +209949 Heat Sink, Primary 1................. .... .............................................

7 199497 Heat Sink, Secondary Assembly 1.................. .... .................................

8 L1 189787 Choke, Input 1........ ...... .... ..................................................

083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High (CE Models) 4.................... .... ...

10 C9 151328 Capacitor, Polyp Met Film .0047Uf 1000 Vdc W/T (CE Models) 1....... ...... .... .......

602 154408 Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent 1................ .... ................

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

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

OM-2226 Page 80

606

2

. Hardware is common and

not available unless listed.

604

604

6

3

1

5

600

7

4

199 497-H

Figure 15-6. Heat Sink, Secondary Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-6. Heat Sink, Secondary Assembly
(Figure 15-5 Item 7)

1 210783 Heat Sink, Secondary 1.................. .... ..........................................

2 D1 204820 Kit, Diode, Ultra Fast 1........ ...... .... ...........................................

3 HD1 198028 Transducer, Current 100a Module Supply V+/− 15v 1....... ...... .... .................

4 RT1 211124 Thermistor, Ntc 30k Ohm @ 25 Deg C 18 in Lead 1....... ...... .... ..................

5 R2, C6 206021 Resistor/Capacitor, 1...... .... .... ............................................

6 R1, C5 199138 Resistor/Capacitor, 1...... .... .... ............................................

7 SR1 199952 Diode, Power Module 50 Amp 600V 1....... ...... .... ...............................

600 207451 Screw, 008−32x .50 Pan Hd−Phl Stl Pld 2................ .... ...........................

606 229331 Screw, M 6−1.0x 16 Pan Hd−phl Stl Pld Sems 2................ .... .....................

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-2226 Page 81

. Hardware is common and

not available unless listed.

199 493-B

Figure 15-7. Base Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 15-7. Base Assembly
(Figure 15-1 Item 5)

1 195644 Base, 1.................. .... ........................................................

2 239388 Bumper, RBR .875 OD x .188 ID x .39 High Recessed 4.................. .... ..............

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-2226 Page 82

Notes

OM-2226 Page 83

SECTION 16 − COOLER PARTS LIST

. Hardware is common and

not available unless listed.

10

3

2

7

15

1

8

6

5

4

9

25

19

13

6

21

26

7

16

14

17

7

15

20

23

24

11

13

12

18

19

22

OM-2226 Page 84

27

28

805 266-A

Figure 16-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 16-1. Main Assembly

1 +235416 Wrapper, ............. .. ........................................................

2 188980 Label, Caution Incorrect Coolant 1.............. .. ...................................

3 203990 Label, Warning General Precautionary Static 1.............. .. .........................

4 235422 Tank, Coolant 1.............. .. ....................................................

5 166608 Cap, Tank Screw−on W/Vent 1.............. .. ......................................

6 237537 Hose, Rbr Brd No 1 X .375 ID X 11.250 Black 1.............. .. ........................

7 237535 Hose, Rbr Brd No 1 X .375 ID X 2.250 Black 3.............. .. .........................

8 166564 Filter, In−line Low Profile 100 Screen 3/8 Hose Bar 1.............. .. ...................

9 235419 Bracket, Filter 1.............. .. ....................................................

10 FM 213072 Fan, Muffin 115V 60 Hz 3400 RPM 6.378 Mtg Holes 1...... .. .. ..................

10 FM 235504 Fan, Muffin 230V 60 Hz 3400 RPM 6.378 Mtg Holes 1...... .. .. ..................

11 235418 Divider 1............. .. ..........................................................

12 237543 Radiator, Heat Exchanger 1............. .. .........................................

13 237538 Hose, Rbr Brd No 1 X .375 ID X 18.000 Black 1............. .. ........................

14 237539 Hose, Rbr Brd No 1 X .375 ID X 11.50 Black 1............. .. .........................

15 237536 Hose, Rbr Brd No 1 X .375 ID X 9.00 Black 2............. .. ..........................

16 235461 Damper, Fluid Pulsation 1............. .. ...........................................

17 MOT 235457 Pump, Assy Coolant (115V) 1...... . .. .......................................

17 MOT 235501 Pump, Assy Coolant (230V) 1...... . .. .......................................

18 PLG1 192457 Cable, Power 11 Ft 7 In 16ga 3c (115V) 1..... . .. .............................

18 PLG1 192458 Cable, Power 11 Ft 7 In 16ga 3c (230V) 1..... . .. .............................

19 235423 Bezel, 2............. .. ..........................................................

20 240279 Valve, Check 3/8 Barb Inline 1............. .. .......................................

21 094263 Clamp, 1−ear Type Nom Dim .718 X .276 Wide 14............. .. ......................

22 235417 Panel, Rear 1............. .. .....................................................

23 235415 Base, 1............. .. ..........................................................

24 019663 Mount, NPRN 15/16 OD x 3/8 Rec 3/16 x 3/8 4............. .. ........................

25 S1 237540 Switch, Rocker Dpst 16 A 115 VAC On−Off 1....... .. .. ..........................

25 S1 237541 Switch, Rocker Dpst 16 A 230 VAC On−Off 1....... .. .. ..........................

26 235499 Ftg, Coolant Barbed 3/8 Tbg 5/8−18 Female 2............. .. .........................

27 Nameplate, Miller Coolmate 1 (Order By Model And Serial Number) 1........................ .....

28 287120 Label, Notice Pump Priming Noise Can Occur During 1............. .. .................

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.

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

OM-2226 Page 85

SECTION 17 − CART PARTS LIST

. Hardware is common and

not available unless listed.

. Item 4 can be mounted in

alternative position if desired.

16

17

12

7

17

1

7

3

4

5

6

2

8

9

10

9

11

1415

6

13

12

Figure 17-1. Cart Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 17-1. Cart Main Assembly

1 235507 Handle, Cart 1.................. .. .............................................

2 227147 Screw, 250−20x .62 Pan Hd−torx Stl Pld Blk Tap−r4.................. .. ............

3 +237593 Tray 1................. .. ....................................................

4 237594 Cable Holder 2.................. .. ............................................

5 235521 Strap, Tie Down 1.000 w X 60.000 lg (300lbs) 2.................. .. ................

6 235527 Bolt, Crg Stl .312−18 X 1.500 Gr2 Pld Zinc Clear 8.................. .. .............

7 195666 Screw, 010−32 x .50 Pan Hd−torx W/Gndrng Stl Pld 7.................. .. ..........

8 235515 Tray, Cooler 1.................. .. .............................................

9 602250 Washer, Flat .812 ID x 1.469 OD x .134t Stl Pld Ansi.750 4.................. .. ......

10 163463 Wheel, Rbr Tire 10.000 OD X 2.000 Wide X .750 Bore 2................. .. ........

11 121614 Ring, Rtng Ext .750 Shaft X .085 Thk E Style Pld 2................. .. .............

12 231184 Nut, 312−18 .50 Hex .27h Stl Pld Sem Cone Wshr.76d 8................. .. ........

13 235517 Bottle Tray Assy, Cart 1................. .. .....................................

14 168663 Hook, spring .250, 2.375 Lg, .312 Snap Opening 4................. .. .............

15 210224 Chain 2................. .. ...................................................

16 +235518 Support, Bottle/Tray 1................ .. ......................................

17 200285 Label, Warning Cylinder May Explode If Damaged 2................. .. ............

805 337-B

Quantity

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.

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

OM-2226 Page 86

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
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Effective January 1, 2010

(Equipment with a serial number preface of MA 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.

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
one year 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
* Engine Driven Welding 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
* Smith 30 Series Flowgauge and Flowmeter

Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)

3. 2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and

Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Work Stations/Weld Tables (No Labor)

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

guarantees or warranties expressed or implied.

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) Guns
* 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 2010−01

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 © 2010 Miller Electric Mfg. Co. 2010−01

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.