Miller Thunderbolt XL User Manual

OM-316 087 083L

September 2001

Processes

Stick (SMAW) Welding

Description

AC/DC, 300/200 AC/DC Models:

225 And 300 Models:

Arc Welding Power Source

R

Thunderbolt XL

Visit our website at

www.MillerWelds.com

AC/DC, 300/200 AC/DC, 225, And 300

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

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

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

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

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

Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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

WARNING

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

25249.5 et seq.)

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

1-3. Additional Installation, Operation, And Maintenance Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – MESURES DE SECURITE CONCERNANT LE SOUDAGE L’ARC 3. . . . . . . . . . . . . . .

1-1. Symboles utilisés 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers concernant le soudage à l’arc 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

le fonctionnement et la maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1-5. Information EMF 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle Charts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Selecting A Location 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Installing Electrode Holder And Work Clamp 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Weld Output Cables 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Electrical Service Guide 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC

And AC/DC Models From 115 Volts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300 Amperes AC

Models From 230 Volts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Connecting Input Power 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE & TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Lubricating Shunt Block And Anti-Noise Adjustment 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Reinstalling Amperage Adjustment Indicator 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – WELDING METHODS & TROUBLESHOOTING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Shielded Metal Arc Welding (SMAW) Procedure 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Electrode And Amperage Selection Chart 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Striking An Arc 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Positioning The Electrode Holder 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Weld Bead Characteristics 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Conditions That Affect Weld Bead Shape 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Electrode Movement During Welding 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Butt Joints 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Lap Joints 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Tee Joints 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PARTS LIST 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

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

som _nd_4/98

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

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

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

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input

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

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

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

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

there is a danger of falling.

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

unit.

D Disconnect input power or stop engine before installing or

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

D Properly install and ground this equipment according to its

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

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

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

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

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

replace cord immediately if damaged – bare wiring can kill.

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

power circuit and machine internal circuits are also

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

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

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

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

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

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

FUMES AND GASES can be hazardous.

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

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

welding fumes and gases.

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

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

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

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

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

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

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

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

OM-316 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

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

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

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

D Wear approved safety glasses with side shields under your

helmet.

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

glare; warn others not to watch the arc.

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

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

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

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

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

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

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

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

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

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

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

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

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch.

MAGNETIC FIELDS can affect pacemakers.

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

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

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

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

D Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

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

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

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

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

OM-316 Page 2

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

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

long enough to extend beyond opposite side of
unit.

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

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

closed and securely in place.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

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

ly correct any interference problem resulting from the installa­tion.

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

equipment at once.

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

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

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading
welding wire.

1-4. Principal Safety Standards

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

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

20402.

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

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

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

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

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

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

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

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

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

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

OM-316 Page 3

1-5. EMF Information

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

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away from opera­tor as practical.

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

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

OM-316 Page 4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

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

Y Identifie un message de sécurité particulier.

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

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

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

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

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

vent être confiés qu’à des personnes qualifiées.

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

ticulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

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

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

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

pas de trous.

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

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

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

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

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

procédé de soudage le demande.

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

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

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

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

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

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

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

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

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

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

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

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

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

sante ou mal épissés.

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

câble distinct.

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

terre ou une électrode provenant d’une autre machine.

circuits internes de l’appareil sont également sous

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

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

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

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

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

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

avec tout objet métallique.

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

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

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

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

D Eloigner votre tête des fumées. Ne pas respirer

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

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

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

tion d’air homologué.

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

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

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

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

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

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

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

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

les fumées.

OM-316 Page 5

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

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

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

pendant le soudage.

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

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

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

trop élevé.

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

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

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

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

(ultraviolets et infrarouges) susceptibles de provoquer

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

D Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent pro­voquer des brûlures graves.

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

d’utiliser le pistolet ou la torche.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

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

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

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

métal chaud.

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

des substances inflammables.

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

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

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

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

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

mité.

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

peut déclencher un incendie de l’autre côté.

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

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

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

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

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

telles qu’un allumeur au butane ou des allumettes.

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

DES PARTICULES VOLANTES
peuvent blesser les yeux.

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

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

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

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

des étincelles et des particules métalliques vo-

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

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

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

LE BRUIT peut affecter l’ouïe.

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

D Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Si des BOUTEILLES sont endomma­gées, elles pourront exploser.

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

manipuler avec précaution.

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

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

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

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

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

cuits électriques.

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

bouteille.

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

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

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

bouteille.

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

lisation ou de branchement de la bouteille.

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

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

font normalement partie du procédé de soudage, les

OM-316 Page 6

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

et la maintenance

Risque D’INCENDIE OU
D’EXPLOSION.

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

mité de surfaces infllammables.

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

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

LA CHUTE DE L’APPAREIL peut
blesser.

D Utiliser l’anneau de levage uniquement pour sou-

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

D Utiliser un engin d’une capacité appropriée pour

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

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

soulever l’appareil.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement, respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

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

recommancer le soudage.

DES ORGANES MOBILES peuvent
provoquer des blessures.

D Rester à l’écart des organes mobiles comme le

ventilateur.

D Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de
protection.

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

D Le rayonnement haute frequence peut provoquer

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

D Demander seulement à des personnes qualifiées familiarisées

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

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

qualifié les interférences résultant de l’installation.

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

reil.

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

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

de sécurité et les ordinateurs.

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

LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir­cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

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

DES ORGANES MOBILES peuvent
provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent pro­voquer des blessures.

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

reçu l’instruction.

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

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

D L’énergie électromagnétique risque de provoquer

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

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

patible électromagnétiquement.

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

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

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

électronique sensible.

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

conformément à ce mode d’emploi.

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

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

commandé par ordinateur tel que les robots.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

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

OM-316 Page 7

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

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

20402.

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

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

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

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

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

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

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

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

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

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

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

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

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

votre corps.

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

vous.

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

soudure.

Consignes relatives aux stimulateurs cardiaques :

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

OM-316 Page 8

2-1. Specifications

SECTION 2 – INSTALLATION

AC/DC Models

Mode

AC

DC

AC

DC

*While idling

Rated Welding Amperage

Output Range

225 A @ 25 V olts AC,

20% Duty Cycle @ 60 Hz;

15% Duty Cycle @ 50 Hz

150 A @ 25 Volts DC,

20% Duty Cycle @ 60 Hz;

15% Duty Cycle @ 50 Hz

300 A @30 Volts AC,

20% Duty Cycle @ 50/60 Hz

200 A @ 25 Volts DC,

20% Duty Cycle @ 50/60 Hz

Height: 18-3/4 in (476 mm); Width: 12-3/4 in (323 mm); Depth: 17-1/2 in (445 mm)

Low: 30 – 150
High: 40 – 235

Low: 40 – 200

High: 65 – 300

Maximum

Open-

Circuit

Voltage

80 VAC

30 – 160 80 VDC

80 VAC

30 – 200 80 VDC

Overall Dimensions

Amperes Input at Rated Load Output

50 Or 60 Hz, Single-Phase

115 V 220 V 230 V 400 V 460 V

95

4.6*

70

5.4*673.6*

47.5

2.3*

23.7

1.2*

39

1.8*341.3*

WeightMode

Weight

104 lb

104 lb

(47 kg)

134 lbs

134 lbs

(61 kg)

Rated Welding Output

225 A @ 25 Volts AC, 20%

Duty Cycle @ 60 Hz;

15% Duty Cycle @ 50 Hz

300 A @ 30 Volts AC,

20% Duty Cycle @ 50/60 Hz

*While idling

AC Models

Amperage

Range

Low: 30 – 150A

High: 40 – 235A

Low: 40 – 200

High: 65 – 300

Max Open-

Circuit

Circuit

Voltage

80 VAC

80 VAC

Overall Dimensions

Height: 18-3/4 in (476 mm); Width: 12-3/4 in (323 mm); Depth: 17-1/2 in (445 mm)

Amperes Input at Rated Load

Output 50 Or 60 Hz, Single-Phase

115 V 220 V 230 V 400 V KW

95

4.6*

70

5.4*

47.5

2.3*

67

3.6*

39

1.8*

7.2

0.22*

11.5

0.22*

WeightRated Welding Output

Weight

85 lb

(39 kg)

107 lb

(49 kg)

OM-316 Page 9

2-2. Duty Cycle Charts

A. For AC/DC Models

2 Minutes Welding 8 Minutes Resting

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

Y 20% Duty Cycle at 225 Amperes. Ex-

ceeding duty cycle can damage unit
and void warranty.

A. For 115/230, 230, And 460 Volt Models

(225/150 Amperes*)

*These models have a 15% duty cycle when used with 50 Hz input power.

B. For AC Models

2 Minutes Welding 8 Minutes Resting

B. For 220, 230/400, And 460 Volt Models

(300/200 Amperes)

SB-086 727 / SB-099 602-A

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

Y 20% Duty Cycle at 225 Amperes. Ex-

ceeding duty cycle can damage unit
and void warranty.

A. For 115/230 And 230 Volt Models

(225 Amperes*)

*These models have a 15% duty cycle when used with 50 Hz input power.

OM-316 Page 10

B. For 220, And 230/400 Volt Models

(300 Amperes)

ST-001 836-A / SB-099 603-A

2-3. Volt-Ampere Curves

A. For AC/DC Models

A. For 115/230, 230 And 460 Volt Models

(225/150 Amperes)

90
80
70
60
50
40

AC Volts

30
20
10

0

0 50 100 150 200 250 300 350

AC Amperes

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

80
70
60
50
40
30

DC Volts

20
10

0

0 50 100 150 200 250

DC Amperes

B. For 220, 230/400, And 460 Volt Models

(300/200 Amperes)

100

90
80
70
60
50

AC Volts

40
30
20

A

10

0

0 50 100 150 200 250 300 350 400 450

B

A

AC Amperes

A=LOW RANGE
B=HIGH RANGE

B

100

90
80
70
60
50

DC Volts

40
30
20

MIN

10

0

0 100 200 300 400

MAX

DC Amperes

193 509 / 193 510 / 193 511 / 193 512

OM-316 Page 11

B. For AC Models

A. For 115/230 And 230 Volt Models

(225 Amperes)

90

80

70

60

50

40

AC Volts

30

20

A

10

0

0 50 100 150 200 250 300

BB

AC Amperes

A

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

A=LOW RANGE

B=HIGH RANGE

B. For 220 Volt Model

(300 Amperes)

90
80
70
60
50
40
30

AC Volts

20
10

0

0 100 200 300 400 500

AC Amperes

C. For 230/400 Volt Model

(300 Amperes)

100

90
80
70
60
50

AC Volts

40
30
20

A

10

0

0 50 100 150 200 250 300 350 400 450

B

A

AC Amperes

A=LOW RANGE
B=HIGH RANGE

B

193 508 / 193 513 / 193 511

OM-316 Page 12

2-4. Selecting A Location

18 in (457 mm) for airflow

1 Rating Label
Locate unit near correct input

power.

Y Special installation may be

1

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

Ref. ST-151 556 / ST-802 105-B

OM-316 Page 13

2-5. Installing Electrode Holder And Work Clamp

3

2

4

1

6

5

Y Turn Off unit and disconnect

input power before installing
electrode holder or work
clamp.

Removing Barrel From Elec­trode Holder

1 Electrode Holder
2 Barrel
3 Access Hole
4 Set Screw
Loosen set screw through access

hole and slide barrel away from
electrode holder.

Installing Electrode Cable and
Barrel onto Electrode Holder

5 Electrode Cable From Unit

(Has Bare Conductors on

End)
6 Terminal Screw
Back out termi n a l s c r e w f r o m e lec-

trode holder. Insert electrode cable
through barrel into end of electrode
holder and tighten terminal screw
securely.

Move barrel toward electrode hold­er and tighten set screw to secure
barrel in place.

Installing Work Cable onto Work
Clamp

7 Work Clamp
8 Work Cable From Unit (Has

Ring Terminal on End)
9 Mounting Bolt
Route work cable through work

clamp as shown and install onto
mounting bolt using supplied hard­ware.

Tools Needed:

1/2 in

1/4 in

2-6. Weld Output Cables

NOTE

OM-316 Page 14

For weld output cable replacements or extensions, contact your Factory
Authorized Service Agent.

8

9

7

ST-802 251 / ST802 105-B

2-7. Electrical Service Guide

Input Voltage

Input Amperes At Rated Output

Max Recommended Standard Fuse Or Circuit Breaker Rating
In Amperes

Min Input Conductor Size In AWG/Kcmil

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG/Kcmil

[ ] Electrical Service Requirements For 300/200 AC/DC And 300 AC Models
Reference: 1997 National Electrical Code (NEC) Ref. S-0092-J

115 220 230 400 460

95 [70]

150 [110]

8 [8]

32 (10) [75 (23)]

8 [8] 12 [10] [14]

47.5
[67]

70

[100]

12

[10]

87 (26)

[82 (25)]

[39]

[60]

[14]

[101
(31)]

138 (42)
[87 (27)]

23.7
[34]

35

[50]

14

[14]

14

[14]

OM-316 Page 15

2-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC

And AC/DC Models From 115 Volts

NOTE

Follow applicable electrical codes and have a competent electrician make internal
connections. Note the input amperes as stated in Section 2-7.

1

Power Switch

S1 Terminals

4
3

To Fan

6

2

2

11

8

To Fan

3

10

4

To Fan

2

8

230V Connection 115V Connection

6

To Fan

7

3

5

2
1

4

5

Tools Needed:

5/16, 3/8 in

(cut tie wraps)

7/16 in

Y Turn Off unit and disconnect input

power.

1 Wrapper
Remove wrapper.
2 Jumper Leads
Cut tie wrap securing jumper leads to power

cord lead and remove jumper leads.
3 Lead 2
4 Lead 3
Remove insulated sleeving, and disconnect

lead 2 from lead 3.
5 Lead 4
6 Power Switch S1 (As Viewed From

Rear Of Switch)
Disconnect lead 4 from terminal 2 on S1.
Connect lead 3 and one end of jumper lead to

terminal 2.
Connect other end of jumper lead to terminal

9

4 on S1. Be sure existing connection to that
terminal remains.

7 230 V Input Power Cord Black Leads
8 Green Ground Lead (On Rear Panel)
Disconnect input power cord black leads from

S1, and disconnect green ground lead from
ground terminal on rear panel.

9 Input Power Cord Strain Relief
Loosen strain relief, and remove 230 volt in-

put power cord.
Obtain correct size and length 115 volt input

power cord (see Section 2-7). Install correct
size ring terminals to cord leads.

Route co r d t h r o u g h s t r a i n r e l i e f , a n d c o n n e c t
green lead to ground terminal.

. To install large power cords, remove

knock-out located on lower rear panel of
unit, insert power cord, and install plug
into original power cord hole.

Ref. 802 247-C

Y Make sure paint has been removed

from area where ground terminal is
secured on unit.

10 115 V Input Power Cord White Lead
Connect lead 2, lead 4, and white input power

cord lead together, and secure with existing
hardware. Reinstall insulated sleeving.

11 115 V Input Power Cord Black Lead
Connect black input power cord lead and

jumper lead to terminal 3 on S1.
Connect other end of jumper lead to terminal

1 on S1.
Use tie-wraps to secure all leads away from

transformer, stabilizer and fan. Be sure leads
are clear of movable shunt.

Tighten strain relief, and install wrapper .
Connect input power according to Section

2-10.

OM-316 Page 16

2-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300

Amperes AC Models From 230 Volts

NOTE

Follow applicable electrical codes and have a competent electrician make internal
connections. Note the input amperes as stated in Section 2-7.

Y Turn Off unit and disconnect

input power.

4

3

2

1

5

6

1 Primary Coil Lead 4
2 Lead 4 Insulation Sleeving
3 Power Switch Lead 4
4 Lead Connection Hardware
Slide Sleeving down, and discon-

nect one lead 4 from the other. Re­move sleeving.

5 Fan Motor (FM) Lead 2
6 Lead 2 Insulation Sleeving
Disconnect fan motor lead 2 at fan

motor, and remove sleeving.
Take lead 2 sleeving and secure it

over the end of primary coil lead 4.
Replace lead 2 sleeving with lead 4

sleeving.
7 Primary Coil Lead 2
Slide sleeving out of the way, and

connect power switch Lead 4 to pri­mary coil lead 2, and secure with
existing hardware. Secure sleeving
over connection.

Connect fan motor lead 2 back onto
fan motor.

Reinstall wrapper.

Connected For 400 Volts

Connected For 230 Volts

7

6

3

2

7

5

Tools Needed:

5/16, 3/8 in

(cut tie wraps)

Ref. ST-802 247

OM-316 Page 17

2-10. Connecting Input Power

Y Disconnect and lockout/tag-

out input power before con­necting input conductors
from unit.

Y Have only qualified persons

make this installation. See
rating label in Section 2-4, and
be sure to supply correct in­put power.

1 Line Disconnect Device
2 Input And Grounding

Conductors For Models Not
Supplied With Plug

See Section 2-7 for conductor and
fuse size and ratings. Size and
ratings must comply with applicable
codes.

3 Plug
4 Proper Receptacle

(User-Supplied)

1

Y Always connect

grounding
conductor first.

2

L2

L1

Install conductors into a deenergized line
disconnect device.

GND/PE

4

3

OM-316 Page 18

ST-802 246

SECTION 3 – OPERATION

3-1. Controls

A. Controls For AC/DC Models

1 Amperage Adjustment Control
2 Power Switch
3 Mode Switch

For DC Weld Output

Use mode switch to select polarity
of dc output, Electrode Posi­tive/DCEP (+),or Electrode Nega­tive/DCEN (–).

For AC Weld Output

Use mode switch to select ac low
range or high range output.

3

2

1

Ref. ST-190 600-B / ST-802 105-B

OM-316 Page 19

B. Controls For AC Models

1 Amperage Adjustment Control
2 Power Switch
3 Mode Switch
Use mode switch to select ac low

range or high range output.

3

1

2

OM-316 Page 20

Ref. ST-190 599-A / ST-802 105-B

SECTION 4 – MAINTENANCE & TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

6 Months

Blow Out Or Vacuum

OR

Inside,

During Heavy Service,

Clean Monthly

4-2. Lubricating Shunt Block And Anti-Noise Adjustment

1

2

2

3

Repair Or

Replace
Cracked

Cables

12 Months

Lubricate Shunt Block

(See Section 4-2)

Y Turn Off welding power

source and disconnect input
power.

1 Wrapper
Remove wrapper.
2 Shunt Block

. Do not grease screw threads

on shunt block.

Apply light coating of high-tempera­ture grease to shaded areas of both
shunt blocks. Turn amperage con­trol handle to spread grease evenly.

3 Noise Adjustment Screws
If shunt block vibrates and

becomes noisy, tighten adjustment
screws 1/4 turn. Install wrapper,
turn On unit, and check for shunt
noise. Repeat procedure until noise
stops. Do not overtighten. Call your
nearest Factory Authorized Ser­vice Agent if noise continues.

Y Install wrapper before

turning On power.

Tools Needed:

1/2 in

5/16 in

ST-802 248-A

OM-316 Page 21

4-3. Reinstalling Amperage Adjustment Indicator

1

5

6

2

7

4

3

3

For 225 A models, X = 2–1/2 in
For 300 A models, X = 2–3/8 in

X

Y Turn Off welding power

source and disconnect input
power.

1 Wrapper
Remove wrapper from unit.
2 Crank Handle
3 Shunt Shaft
4 Transformer And Shunt

(Located Inside Unit)

Insert crank handle onto shunt
shaft protruding through front panel
and turn crank handle to adjust
shunt to the proper vale of “X”, de-
pending on model (see detail of
transformer and shunt.

Remove crank handle.
5 Pinion Gear
Install pinion gear onto front panel

making sure anti-rotation pins are in
holes on front panel.

6 Pointer Gear
Install pointer gear overtop of pinion

gear and rotate so pointer is indicat­ing 130 Amps on ac Low Range
scale (see example).

Install crank handle overtop the sta­tor/pinion gear assembly with the
handle straight down. It may be
necessary to turn the handle slight­ly so vertical alignment is possible.

7 Securing Screw
Install securing screw through han-

dle, into threaded hole in shunt
shaft. Tighten securely.

Reinstall wrapper.

OM-316 Page 22

Viewed from right side of unit.

Proper alignment of pointer and crank handle.

Tools Needed:

T-20 Torx

5/16 in

ST-802 248-A

4-4. Troubleshooting

Trouble Remedy

No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 2-10).

Check and replace line fuses if open. Reset breakers if necessary (see Section 2-10).
Fan does not run; weld output okay. Be sure nothing is blocking movement of fan. If fan does not run freely, replace fan motor.
Erratic weld current. Clean and tighten all weld cable connections.
Erratic arc with excessive spatter. Use dry, properly stored electrodes.

Shorten arc length.

Reduce amperage setting (see Section 3-1).
Electrode freezing to work. Increase amperage setting (see Section 3-1).

Increase arc length.

Use dry, properly stored electrodes.
Noise and vibration from shunt block. Lubricate shunt block and/or tighten adjustment screws (see Section 4-2).

SECTION 5 – ELECTRICAL DIAGRAMS

Figure 5-1. Circuit Diagram For AC/DC (230 Volts) Models

SA-191 364

OM-316 Page 23

Figure 5-2. Circuit Diagram For AC/DC (460 Volts) Models

SA-191 365

PLG1

GRN

S1

CONNECTED FOR 230 VOLTS

S1

PRI

1 23 4

T1

SEC

S2

NEUTRAL
(WHT)

LINE
(BLK)

GRN

PLG1

CONNECTED FOR 115 VOLTS

S1

FMFM

PRI

123

T1

SR1

R

4

Z1

OM-316 Page 24

WORK ELECTRODE

Figure 5-3. Circuit Diagram For AC/DC (115/230 Volts) Models

SA-191 363-A

220

VOLT

ONLY

POWER

CORD

GRN

S1

T1

FM

PRI

SEC

S.O.P.

SR1

S.O.P.

POWER

CORD

S2

WORK ELECTRODE

Figure 5-4. Circuit Diagram For 300/200 AC/DC (220 Volts) Models

GRN

S1

CONNECTED FOR 400 VOLTS

230V

CONNECTED FOR 230 VOLTS

FMFM

PRI

1234 4

PRI

132

R

Z1

SA-191 368

T1

SEC

T1

SR1

S2

WORK ELECTRODE

Figure 5-5. Circuit Diagram For 300/200 AC/DC (230/400 Volts) Models

R

OM-316 Page 25

Z1

SA-191 369

S1

460

VOLT

ONLY

POWER

CORD

GRN

230V

FM

PRI

T1

SEC

S.O.P.

S.O.P.

SR1

S2

WORK ELECTRODE

Figure 5-6. Circuit Diagram For 300/200 AC/DC (460 Volts) Model

R

Z1

SA-191 370

230

VOLT

ONLY

PLG1

GRN

S1

S2

T1

WORK

FM

PRI

SEC

AC HIGH
AC LOW

ELECTRODE

SA-191 362

OM-316 Page 26

Figure 5-7. Circuit Diagram For 225 (230 Volts) Models

S1

CONNECTED FOR 230 VOLTS

NEUTRAL
(WHT)

CONNECTED FOR 115 VOLTS

PLG1

GRN

S1

S2

LINE
(BLK)

S1

GRN

PLG1

PRI

1 23 4

T1

SEC

WORK

ELECTRODE

Figure 5-8. Circuit Diagram For 225 (115/230 Volts) Models

PRI

123

T1

FMFM

4

SA-191 361-A

220

VOLT

ONLY

POWER

CORD

GRN

S1

S2

T1

WORK

FM

PRI

SEC

AC HIGH

AC LOW

S.O.P.

ELECTRODE

Figure 5-9. Circuit Diagram For 300 (220 Volts) Models

SA-191 366

OM-316 Page 27

S1

CONNECTED FOR 400 VOLTS

CONNECTED FOR 230 VOLTS

POWER

CORD

GRN

230V

FMFM

PRI

1234 4

T1

132

T1

PRI

SEC

S2

WORK

ELECTRODE

Figure 5-10. Circuit Diagram For 300 (230/400 Volts) Models

SA-191 367

OM-316 Page 28

SECTION 6 – WELDING METHODS & TROUBLESHOOTING

mod5.1* 9/92

A. Welding Methods

6-1. Shielded Metal Arc Welding (SMAW) Procedure

5

4

2

1

7

Tools Needed:

1 Workpiece
Make sure workpiece is clean before welding.
2 Work Clamp
Place as close to the weld as possible.
3 Electrode
A small diameter electrode requires less current than a large one.

Follow recommendations of electrode manufacturer when setting
weld amperage (see 6-2).

4 Insulated Electrode Holder

3

6

ST-151 593

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.

Y Welding current starts as soon as electrode touches the

workpiece.

7 Slag
Use a chipping hammer and wire brush to remove slag. Remove

slag and check weld bead before making another weld pass.

OM-316 Page 29

6-2. Electrode And Amperage Selection Chart

DIAMETER

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

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

50

100

150

200

RANGE

AMPERAGE

250

300

350

400

450

OM-316 Page 30

AC

ELECTRODE

6010
6011
6013

7014
7018

7024

NI-CL

308L

EP
EP

EP,EN
EP,EN

EP

EP,EN

EP
EP

DC*

POSITION

ALL
ALL
ALL

ALL
ALL

FLAT

HORIZ

FILLET

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW
MED

LOW HYDROGEN,

LOW

LOW
LOW

LOW

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

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

Ref. ST-087 985-A

6-3. Striking An Arc

Scratch Start Technique

Tap Start Technique

1 Electrode

1

2

3

1

2

3

2 Workpiece
3 Arc
Drag electrode across workpiece

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

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

6-4. Positioning The Electrode Holder

90° 90°

End View Of Work Angle Side View Of Electrode Angle

45°

45°

10°–30°

10°–30°

S-0049 / S-0050

Groove Welds

Fillet Welds

End View Of Work Angle Side View Of Electrode Angle

S-0660

OM-316 Page 31

6-5. Weld Bead Characteristics

Poor Weld Bead

Good Weld Bead

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding

1

2

1

2

3

3

4

4

5

5

4 Bad Overlap
5 Poor Penetration

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.

4 No Overlap
5 Good Penetration Into Base

Metal

6-6. Conditions That Affect Weld Bead Shape

Electrode Angle

Angle Too Sm a ll

Arc Length

Too Short

Correct Angle

10° - 30°

Drag

Normal

Ref. S-0052-B

Angle Too Large

Spatter

Too Long

Travel Speed

OM-316 Page 32

Slow Normal Fast

S-0061

6-7. Electrode Movement During Welding

1

3

2

6-8. Butt Joints

1 Stringer Bead – Steady Move-

ment 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.

. A single stringer bead is

satisfactory for most narrow

groove weld joints. For wide

groove weld joints or bridging

across gaps, a weave bead

works better.

S-0054-A

1 Tack Welds
Prevent edges of joint from drawing

together ahead of electrode by tack

2

1/16 in

1

3

4

(1.6 mm)

30°

welding the materials in position be­fore final weld.

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

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

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

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

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

in (5 mm).

S-0662

OM-316 Page 33

6-9. Lap Joints

2 3

Single-Layer Fillet Weld

6-10. Tee Joints

2

1

45°

Or Less

1 Electrode

30° Or Less

11

Multi-Layer Fillet Weld

2

30° Or Less

3

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

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

1 Electrode
2 Fillet Weld

1

Keep ar c short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.

For maximum strength weld both
sides of uprig h t s e c t i o n .

3 Multi-Layer Deposits
Weld a second layer or more when

a larger fillet is needed. Use any of
the weaving patterns shown in Sec­tion 6-7. Remove slag before mak ­ing another weld pass.

S-0063 / S-0064

S-0069 / S-0058-A / S-0061

B. Welding Troubleshooting

Table 6-1. Porosity

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

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

welding.

OM-316 Page 34

Table 6-2. Excessive Spatter

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

Possible Causes Corrective Actions

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

Table 6-3. Incomplete Fusion

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

Possible Causes Corrective Actions

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

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

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

welding.

Table 6-4. Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

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

Reduce travel speed.

OM-316 Page 35

Table 6-5. Excessive Penetration

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

Excessive Penetration

Good Penetration

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

Table 6-6. Burn-Through

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

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

Table 6-7. Waviness Of Bead

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

Table 6-8. Distortion

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.

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

Distortion – contraction of weld metal dur-
ing welding that forces base metal to
move.

OM-316 Page 36

Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.

Notes

OM-316 Page 37

12

SECTION 7 – PARTS LIST

6

. Hardware is common and

not available unless listed.

16

17

11

10

9

13

15

18

19

20

7

8

6

5

4

2

1

14

21

3

29

27

21

28

25

22

23

24

25

26

OM-316 Page 38

SA-802 245-B

Figure 7-1. Main Assembly (AC/DC model illustrated)

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 7-1. Main Assembly

1 134 464 LABEL, gen precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 190 144 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 S2 190 079 SWITCH, secondary 2-position (AC 225 model) & (AC 300 model) 1. . . . . . . . . . . . . . . . . . .

3 S2 190 080 SWITCH, secondary 4-position (AC/DC 225 model) & (AC/DC 300 model) 1. . . . . . . . . . . . .

4 190 977 BUS BAR, jumper (AC/DC 225 model) & (AC/DC 300 model) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 190 978 BUS BAR, jumper (AC/DC 225 model) & (AC/DC 300 model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 191 122 BRACKET, base reinforcing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 T1 190 170 TRANSFORMER & SHUNT, (230V 225A model) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . .

7 T1 192 467 TRANSFORMER & SHUNT, (460V 225A model) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . .

7 T1 192 468 TRANSFORMER & SHUNT, (115/230V 225A model) (consisting of) 1. . . . . . . . . . . . . . . . . .

7 T1 192 179 TRANSFORMER & SHUNT, (220V 300A AC/DC model) (consisting of) 1. . . . . . . . . . . . . . .

7 T1 192 317 TRANSFORMER & SHUNT, (220V 300A AC model) (consisting of) 1. . . . . . . . . . . . . . . . . . .

7 T1 192 326 TRANSFORMER & SHUNT, (230/400V 300A model) (consisting of) 1. . . . . . . . . . . . . . . . . .

7 T1 192 469 TRANSFORMER & SHUNT, (460V 300A model) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . .

8 190 242 SCREW, lead shunt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 190 150 SHUNT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 147 907 SCREW, 5/16-18 x 1.75 w/loctite 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 080 522 BLOCK, anti-noise shunt 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Z1 190 145 STABILIZER, (AC/DC 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Z1 192 177 STABILIZER, (AC/DC 300A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 SR1 190 303 RECTIFIER, (AC/DC 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 SR1 190 965 RECTIFIER, (AC/DC 300A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 S1 124 511 SWITCH, (all 225A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 S1 045 834 SWITCH, (all 300A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 190 086 CASE SECTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 PLG1 088 297 CORD SET (230V 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 071 906 CABLE (460V 225A model) & (115/230V 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 204 141 CABLE (all 300A models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 111 443 BUSHING, strain relief (230V 225A model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 604 102 CONNECTOR (all 300A models), (460V 225A model) & (115/230V model) 1. . . . . . . . . . . . . . .

18 185 759 LABEL, warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 FM 190 234 MOTOR, fan (all models except 115/230V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 FM 191 864 MOTOR, fan (115/230V models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 005 656 BLADE, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 190 599 PANEL, output (AC 225A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 190 600 PANEL, output (AC/DC 225A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 192 119 PANEL, output (AC 300A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 192 120 PANEL, output (AC/DC 300A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 190 296 GEAR, pinion 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 190 295 GEAR, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 190 241 HANDLE, control current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 190 538 LEAD LIST 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 190 584 KIT, electrode holder & gnd clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 LABEL, brand (order by model & serial no.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 148 956 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 190 243 CLAMP, weld cable 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

Note: “225A model” and “300A model” refers to the AC output rating of the AC/DC and the AC only machines.

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-316 Page 39

Notes

OM-316 Page 40

Warranty Questions?

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

Y our distributor also gives
you ...

Service

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

Support

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

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous 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 date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.

1. 5 Years Parts – 3 Years Labor

* Original main power rectifiers
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by
the engine manufacturer .)

3. 1 Year — Parts and Labor

* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185 & Spoolmate 250
* Canvas Covers

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.

2. Items furnished by 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 bas e d u p o n a c tual 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. I N N O 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 7/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: [phone] Auto-A t t ended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters –
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier for:

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

PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01

File a claim for loss or damage during
shipment.