Miller Electric 1000, 1250 User Manual

OM-2221 186 183V

2008−01

Processes

Processes

Submerged (SAW) Welding

Description

Arc Welding Power Source

™

Summit Arc 1000/1250

Visit our website at

www.MillerWelds.com

File: Submerged (SAW)

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 2005−04

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 3 − INSTALLATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle and Overheating 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Dimensions And Weight 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Symbol Definitions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Manufacturer’s Rating Label For CE Products 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Selecting a Location 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Weld Output Terminals and Selecting Cable Sizes 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Selecting AC or DC Output 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Terminal Strip TE3 and Remote 14 Receptacle RC7 Information 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Basic Sub Arc (SAW) Welding 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Connecting Remote Control 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. 115 Volts AC Receptacle And Circuit Breaker (460 And 575 Volt Input Models) 15 . . . . . . . . . . . . . . . . . .

3-14. 230 Volts AC Receptacle And Circuit Breakers (400 Volt Input Models) 15 . . . . . . . . . . . . . . . . . . . . . . . .

3-15. Electrical Service Guide 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Connecting Input Power 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17. Matching Primary Lines L1, L2, And L3 When Using Multiple AC Units 18 . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − MAKING WELD OUTPUT CONNECTIONS 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Work And Electrode Cable Connections For Single DC or AC Arcs 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Using Multiple Units: DC Lead Arc, One or More AC Trailing 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Using Multiple Units: Two or More AC Arcs 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Using AC Arcs Terminal Strip TE4 Connections 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Control Board PC1 Connections 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Front Panel Controls (Non-CE Models) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Front Panel Controls (CE Models) 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Fuses F1 And F2 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Access Area Supplementary Protectors 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Troubleshooting 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES
WARRANTY

Declaration of Conformity for

European Community (CE) Products

. This information is provided for units with CE certification (see rating label on unit).

Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E

20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]

European Contact Signature:

Declares that the product: Summit ArcE 1000/1250

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 72/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Electromagnetic Compatibility Directives: 89/336, 92/31/EEC

Standards

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1993

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

(April 1995 − Draft revision)

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

dec_stat_1/07

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: January 1997

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

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

1-1. Symbol Usage

OM−2221 8/08 − som _2007−04

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

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).

D Properly install and ground this equipment according to its

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

power circuit and machine internal circuits are also

. 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 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-type
welding power sources after removal of input
power.

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

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

HOT PARTS can cause severe burns.

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

torch.

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

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

OM-2221 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.

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 fil-

ter lenses 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,

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

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

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

WELDING can cause fire or explosion.

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.

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.

MAGNETIC FIELDS can affect Implanted
Medical 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.

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.

OM-2221 Page 2

workpiece, and hot equipment can cause fires and

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 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.

FLYING SPARKS can cause injury.

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.

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.

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

guards for maintenance as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine replacement parts from the

manufacturer.

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.

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-2221 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.

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).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, 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).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,

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.

Ontario, Canada L4W 5NS (phone: [phone] or in Toronto
416-747-4044, website: www.csa-international.org).

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

25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).

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

P.O. Box 9101, Quincy, MA 02269-9101 (phone: [phone], web­site: 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, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic 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 power­frequency 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, or using a
cable cover.

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 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-2221 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

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

sous tension lorsque le courant est délivré à la

(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_2007−04

OM-2221 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans

s

e

­r

e

o
e

e

e

u
n

e

f

e

les sources de soudage onduleur quand on a
coupé l’alimentation.

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.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

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 êtr
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 pr
voquer des brûlures dans les yeux
sur la peau.

Le rayonnement de l’arc du procédé de soudag

(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 pendant le soudage
(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-2221 Page 6

génère des rayons visibles et invisibles intense

LE SOUDAGE peut provoquer un in
cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites pe

provoquer leur éclatement. Des étincelles peuve
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchau
fement ou un incendie. Avant de commencer le soudage, vérifier
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.

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

­n
u

-

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 MAGNETIQUES peuv­ent affecter des implants médicaux.

D Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

D 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.

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 de

dage, les manipuler avec précaution.

gaz font normalement partie du procédé de sou-

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.

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’APPAREIL peut
blesser.

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.

L’EMPLOI EXCESSIF peut SUR­CHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; re-

specter 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.

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

stance inflammable.

LES ÉTINCELLES VOLANTES ris­quent de 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. Cette manœuv
re est à exécuter dans un endroit sûr lorsque l’o
porte l’équipement homologué de protection d
visage, des mains et du corps.

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 antistati-

ques 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.

OM-2221 Page 7

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 per-

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

DES ORGANES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protec­tion.

D Seules des personnes qualifiées sont autorisées à enlever les

portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.

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 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

D N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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 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.

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

D L’énergie électromagnétique risque de provo-

quer 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.

Pour les moteurs à essence :

Pour les moteurs diesel :

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.

OM-2221 Page 8

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).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, 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, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.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).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.

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 électromagnéti­ques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, 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,

11 West 43rd Street, New York, NY 10036-8002 (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 télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance 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. Connecter la pince sur la pièce aussi près que possible de la
soudure.

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-2221 Page 9

OM-2221 Page 10

3-1. Specifications

Volt

A

M

100% Duty Cycle;

2

V

250−1250 A

1 V

143

124

114

100

SECTION 3 − INSTALLATION

AC or DC

Rated Output

1000 A at 44 V,

100% Duty Cycle;

1250 A at 44 V,

60% Duty Cycle

*While idling

age

Range in

CV Mode

5−44

mperage
Range in
CC Mode

3-2. Duty Cycle and Overheating

100% Duty Cycle At 1000 Amperes

RMS Amps Input at Rated Load Output, 3-Phase at

ax. Open-

Circuit

Voltage

Continuous Welding

­380/400/415 V

(50/60 Hz)

7

NEMA Load

Voltages and Class I Rating

460 V

(60 Hz)

143 124 114 100 98 53
(3*)

(3*)

500 V

(50/60 Hz)

(3*)

575 V

(60 Hz)

(3*)98(2.37*)53(0.95*)

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

If unit overheats, high temperature
shutdown light turns On, thermo­stat(s) opens, output stops, and
cooling fan runs. Wait fifteen min­utes for unit to cool. Reduce amper­age or duty cycle before welding.

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

KVA KW

Overheating

0

Minutes

A/V

15

OR

Reduce Duty Cycle

duty1 4/95 − 181 560

OM-2221 Page 11

3-3. Volt-Ampere Curves

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

A. CC Mode

DC Output

DC Output

AC Output

B. CV Mode

AC Output

OM-2221 Page 12

va_curve1 4/95 − 189 242 / 189 240 / 189 243 / 189 241

3-4. Dimensions And Weight

Dimensions

Height* 44 in (1118 mm)

Width* 27-1/4 in (692 mm)

Depth* 46 in (1168 mm)

A

Weight

1225 lb (540 kg)

A 1-7/8 in (48 mm)

B 44-1/8 in (1120 mm)

C 11/16 in (17 mm)

D 26-1/16 in (662 mm)

4 holes:
21/32 in (6.5 mm) dia

E

* Includes lifting eye, handles, hardware, etc.

3-5. Symbol Definitions

. Some symbols are found only on CE products.

A

Amperage

Alternating Current

(AC)

V

B

E

Front

C

D

Voltage

Panel/Local Line Connection Three Phase

Hz

Hertz

Direct Current

(DC)

U

I

1eff

Submerged Arc

Welding (SAW)

Conventional Load

2

Maximum Effective

Supply Current

Gas Metal Arc

Welding GMAW)

Output On Voltage Input Off

Percent

Voltage

Increase

U

I

2

IP

Read Operator’s

Voltage (Average)

0

Manual

Rated No-Load

Rated Welding

Current

3-Phase Power

Source With

AC/DC Output

Degree Of

Protection

U

1

Remote

Rated Supply

Voltage

Protective Earth

(Ground)

Temperature

Air Carbon Arc

Cutting (CAC-A)

X

I

1max

Duty Cycle

Circuit Breaker

(Supplementary

Protector)

Rated Maximum

Supply Current

Ventilating And Air

Circulating Fan

Shielding Metal Arc

Welding (SMAW)

OM-2221 Page 13

3-6. Manufacturer’s Rating Label For CE Products

3-7. Selecting a Location

Movement

1

Location

OR

5

3

18 in

(460 mm)

1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to

move unit.
If using lifting forks, extend forks

beyond opposite side of unit.
3 Rating Label
4 Plate Label
Use rating or plate label to deter-

mine input power needs.

2

5 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.

OM-2221 Page 14

4

18 in

(460 mm)

loc_2 3/96 - 801 881-A

3-8. Weld Output Terminals and Selecting Cable Sizes

Weld Output

Weld Output

5/8 in diameter holes

15/16 in

. In the table below, when multiple numbers are indicated separated by a hyphen, the number to the left of the hyphen indicates how many cables

are to be used, and the number to the right indicates the size of the cable to be used. For example, 3-3/0 indicates that 3 cables of 3/0 gauge need
to be used for electrode and work connections.

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Weld Output

Terminals

! Turn Off welding pow-

er source and discon­nect input power be­fore connecting to
weld output termi­nals.

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

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

Electrode

Terminals

Requires cable lugs with

*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. Contact your
distributor for the mm2 equivalent weld cable sizes. S-0007-E

Work

Terminals

15/16 in

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

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

.

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0

1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

1250 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

10 − 60%

Duty Cycle

60 − 100%

Duty Cycle

10 − 100% Duty Cycle

OM-2221 Page 15

3-9. Selecting AC or DC Output

Ï

Ï

A/V AMPERAGE

REMOTE VOLTAGE SENSING

2

AC

1

! Turn Off welding power

source and disconnect input
power before relinking unit.

Remove top of unit.
1 AC/DC Output Selection

Label (Located Inside Unit)
2 Jumper Links
Locate terminal board inside unit.

Install jumper links for desired out­put as shown on label.

. Securing nuts must be re-

DC

moved to change the position

of the three jumper links at the

right of the terminal board. To

change the position of the re-

maining six jumper links, loos-

en the securing nuts only to al-

low the slotted jumper links to

be moved. Always securely re-

tighten nuts after links are

moved.

Reinstall top of unit.

! See Safety Rules at begin-

ning of manual for special

AC concerns.

Tools Needed:

3/8, 11/16, 7/8 in

3-10. Terminal Strip TE3 and Remote 14 Receptacle RC7 Information

24 VOLTS AC

REMOTE OUTPUT CONTROL

115 VOLTS AC

GND

42 VOLTS AC

A/V AMPERAGE

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

* Not Used

Socket

on RC7

A A 24 volts, 12 amperes, AC. Protected by circuit breaker CB2.
B B Contact closure to A completes 24 volts AC contactor control circuit.
C C Command reference; +10 volts DC.
D D Remote control circuit common.
E E 0 to +10 volts DC input command signal from remote control.

I I 115 volts, 12 amperes AC. Protected by circuit breaker CB1.

J J Contact closure to I completes 115 volts AC contactor control circuit.

K
G

* L

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

* N Voltage sensing signal from Work weld output terminal.
* P Voltage sensing signal from Electrode weld output terminal.

Terminal

on TE3

K
G

Information

Chassis common.
Circuit common for 24, 42 and 115 volts AC circuits.

42 volts, 12 amperes AC. Protected by circuit breaker CB3.

801 881-A / Ref. S-185 482

OM-2221 Page 16

3-11. Basic Sub Arc (SAW) Welding

. Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive assembly cable, drive rolls, gun,

welding wire, weld cables, remote voltage sense leads, and flux system for the desired application.

A. Basic Sub Arc (SAW) Equipment Connections

! Turn off welding power

source and weld control, and
disconnect input power be­fore making connections.

. Use remote voltage sense

leads in all applications.

. Suggested size for remote volt-

age sense wire is 12 gauge or
larger.

. For better performance for

most Sub Arc (SAW) applica­tions, make connections to the
high inductance weld output
terminal.

. Polarity: For DCEP (Reverse

Polarity), connect weld cables
and voltage sense leads as
shown. For DCEN (Straight
Polarity), reverse weld cables
and voltage sense leads.

Electrode Work

A
B
C
D
E
G

J
K
L
N
P

Summit Arc 1000/1250

Weld Cables

From Terminal

Strip 1T Terminal P

14-Pin Welding

Power Source

Control Cord

From Terminal Strip

10-Pin Motor

Control Cord

1T Terminal N

HDC Controller

Workpiece

Flux System

Flux

Valve

Wire
Drive

Assembly

804 738-A

OM-2221 Page 17

B. Remote Voltage Sensing Leads Placement Guidelines For A Single Arc (Required)

Remote Voltage
Sense Leads

Welding Power

Source

Work
Clamp

BAD

Sense lead is affected by weld
current.

Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.

Remote Voltage
Sense Leads

Work
Clamp

Welding Power

Source

BEST

Sense leads are out of the current
paths.

Sense leads detect arc voltage ac­curately.

Best starts, arcs and most reliable
results.

OM-2221 Page 18

Ref. 804 108-A

C. Sensing Leads Placement Guidelines For Multiple Arcs

Work
Clamp

Trail

Trail

Remote Voltage
Sense Leads

Remote Voltage

Sense Leads

Lead

Work
Clamp

Trail

Remote Voltage Sense Leads

Lead

Lead

Remote Voltage
Sense Leads

Work
Clamp

Lead

Welding Power

Source

Trail

Welding Power

Source

Lead

Welding Power

Source

Trail

Welding Power

Source

BAD

Current flow from lead affects trail
sense.

Current flow from trail affects lead
sense.

Neither sense lead picks up the
correct work voltage, causing
starting and welding arc instability.

BETTER

Lead sense is only affected by
weld current from lead.

Trail sense lead is only affected
by weld current from trail.

Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.

Trail

Trail

Lead

Remote Voltage Sense Leads

Remote Voltage

Sense Leads

Lead

Work
Clamp

Trail

Lead

Lead

Welding Power

Source

Trail

Welding Power

Source

BEST

Both sense leads are out of the
current paths.

Both sense leads detect arc volt­age accurately.

No voltage drop between lead and
trail sense.

Best starts, arcs and most reliable
results.

Ref. 804 108-A

OM-2221 Page 19

3-12. Connecting Remote Control

OR

3

A

B
C

D

E
G

I
J
K

L

N
P

OR

OR

1

B
C

D

! Turn Off welding power

source and disconnect input
power before opening ac­cess door.

1 Access Door
2 Remote 14 Receptacle

(Mounted Inside Access Area)

Connect remote control to Remote
14 receptacle. If plug does not fit,
wire cord to terminal strip TE3 (see
Section 3-10 for terminal
information).

3 Terminal Strip TE3 (Mounted

Inside Access Area)

4 Lead Being Connected To

TE3
5 Securing Screw
Strip 3/8 in (10 mm) insulation off

end of lead, insert end into proper
location on TE3, and tighten appli­cable securing screw.

Close and secure access door.

AJ

K

I

L

NH

M

G

F

E

2

OM-2221 Page 20

3

4

3/8 in

(10 mm)

5

Tools Needed:

801 882-A

3-13. 115 Volts AC Receptacle And Circuit Breaker (460 And 575 Volt Input Models)

1 115 V 12 A AC Receptacle
Power is shared between the du-

plex receptacle and the 115 volt
output connections at terminal strip
TE3 and the Remote 14 receptacle
(see Section 3-10).

1

2

2 Circuit Breaker CB1
CB1 protects 115 volts AC recep-

tacle and 115 volts AC portion of
terminal strip TE3 and Remote 14
receptacle from overload.

Ref. 175 086 / Ref. 801 882-B

3-14. 230 Volts AC Receptacle And Circuit Breakers (400 Volt Input Models)

1 230 V 16 A AC Receptacle
2 Circuit Breaker CB1
CB1 protects the 115 volts AC por-

tion of terminal strip TE3 and Re­mote 14 receptacle from overload.

3 Circuit Breaker CB4
CB4 protects the 230 volts AC re-

ceptacle from overload.

1

3

2

Ref. 175 086 / Ref. 801 882-B

OM-2221 Page 21

3-15. Electrical Service Guide

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

Three-Phase, 50/60 Hz Three-Phase, 60 Hz

Input Voltage 380 400 415 500 460 575

Input Amperes At Rated Output 149 141 136 11 3 123 98

Max Recommended Standard Fuse Rating In Amperes

Time-Delay

Normal Operating 3 225 200 200 175 175 150

Min Input Conductor Size In AWG 4 1/0 1/0 1/0 2 1 3

2

1

175 175 150 125 150 110

Max Recommended Input Conductor Length In Feet (Me­ters)

Min Grounding Conductor Size In AWG 4 4 6 6 6 6 6

Reference: 2005 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” .

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

398 (121) 441 (134) 474 (145) 490 (149) 482 (147) 548 (167)

OM-2221 Page 22

3-16. Connecting Input Power

= GND/PE Earth Ground

8

7

10

9

4

6

1

2

4

=

GND/

Tools Needed:

3

PE Earth Ground

7/16 in

3/8 in

3/16 in

L3 (W)
L1 (U)

6

L2 (V)

5

3

Input Contactor

! Installation must meet all National and

Local Codes − have only qualified per­sons make this installation.

! Disconnect and lockout/tagout input

power before connecting input conduc­tors from unit.

! Make input power connections to the

welding power source first.

! Always connect green or green/yellow

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

! When using multiple units which will be

linked with the synchronizing terminal
strip TE4, ensure that primary input pow­er conductors are connected to each unit
in the same sequence (L1 to L1, L2 to L2,
and L3 to L3.)

. See Section 3-17 for information on testing

for proper primary phase sequence.

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

Remove left side panel.
1 Input Power Conductors (Customer

Supplied Cord)

Select size and length of conductors using
Section 3-15. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage capac­ity and correct hole size.

Welding Power Source Input Power Connec­tions

2 Strain Relief
Route conductors (cord) through strain relief and

tighten screws.
3 Machine Grounding Terminal
4 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding con­ductor to welding power source grounding termi­nal first.

5 Welding Power Source Line Terminals
6 Input Conductors L1 (U), L2 (V) And L3

(W)

Connect input conductors L1 (U), L2 (V) and L3
(W) to welding power source line terminals.

Reinstall left side panel.

Disconnect Device Input Power Connections

7 Disconnect Device (switch shown in OFF

position)

8 Disconnect Device (Supply) Grounding

Terminal

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

9 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And L3

(W) to disconnect device line terminals.
10 Overcurrent Protection
Select type and size of overcurrent protection us-

ing Section 3-15 (fused disconnect switch
shown).

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

input_2 3/96 - Ref. 144 221 / Ref. 801 883-B

OM-2221 Page 23

3-17. Matching Primary Lines L1, L2, And L3 When Using Multiple AC Units

! Turn Off welding power

source and disconnect input
power before opening ac­cess door.

This test must be performed on the
units that will be interconnected us­ing the synchronizing terminal strip
TE4. This refers to the multiple unit
hook-ups shown in Sections 4-2
and 4-3.

Power On both units. Using an AC
voltmeter, measure the voltage be­tween terminal A of terminal strip
TE3 on both units as shown.

If the measured voltage is approxi­mately 0 (zero) volts, the primary
lines are properly phased.

If the measured voltage is approxi­mately 53 volts, swap the input con­ductor connections to L1 and L3 on
the primary input contactor of unit
B.

If the measured voltage is approxi­mately 46 volts, swap L1 and L2 on
the primary input contactor of unit
B. The meter will then read either
approximately 53 volts or approxi­mately 26 volts. If the meter reads
approximately 53 volts, swap L1
and L3. If the meter reads approxi­mately 26 volts, swap L2 and L3.

If the measured voltage is approxi­mately 26 volts, swap L1 and L2 on
the primary input contactor of unit
B. The meter will then read either
approximately 0 (zero) volts or
approximately 46 volts. If the meter
reads approximately 0 volts, the pri­mary lines are properly phased. If
the meter reads approximately 46
volts, swap L1 and L2 again, and
swap L2 and L3.

When the second unit’s primary line
phase sequences are matched with
the first unit, test primary phasing
between third unit (if applicable)
and second unit. Always test and
correct phasing between following
unit and unit previous to it.

Meter Polarity Does Not Matter

A
B
C
D
E
G

I
J
K
L
N
P

Terminal Strip

TE3

Unit A

(First Unit)

Set on AC Volts Scale

A
B
C
D
E
G

I
J
K
L
N
P

Terminal Strip

TE3

Unit B

(Second Unit)

OM-2221 Page 24

L1

L2

Input Contactor

L3

Ref. 801 882-A / Ref. 801 883-B

SECTION 4 − MAKING WELD OUTPUT CONNECTIONS

4-1. Work And Electrode Cable Connections For Single DC or AC Arcs

! Turn Off welding power

source and disconnect input
power before opening access
door.

! High weld output current haz-

ard! Remove all metal jewelry,
such as rings and watches,
and be careful with tools near
output terminals. High current
can cause severe burns from
hot metal if touched to output
terminals and unit is On. AL­WAYS turn Off welding power
sources and disconnect input
power BEFORE making weld
output connections.

! ELECTRIC SHOCK can kill.

Do not touch live electrical parts.
Turn off welding power sources and

disconnect input power before mak­ing any weld output connections.

See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q

To Electrode

Connections For

DC Electrode Positive

Or AC Output

To Electrode

To Work

To Work

Connections For

DC Electrode Negative

Or AC Output

(addresses at beginning of manual).
Do not handle or come in contact with

two live electrodes at the same time.

! Undersized weld cables can

cause fire.

Work cable or electrode cable must
be able to carry the weld output of the
individual welding power source (see
Section 3-8).

Do not exceed duty cycle of welding
power sources.

! If there are any questions re-

garding this procedure, con­tact the factory before con­necting units.

For DC electrode positive:

Connect the proper size and number
of weld output cables (see Section
3-8) to one of the welding power
source electrode terminals.

Connect the proper size and number
of ground cables to one of the welding
power source work terminals.

For DC electrode negative:

Connect the proper size and number
of weld output cables (see Section
3-8) to one of the welding power
source work terminals.

Connect the proper size and number
of ground cables to one of the welding
power source electrode terminals.

For AC output:

Connect the proper size and number
of weld output cables (see Section
3-8) to one of the welding power
source electrode terminals.

Connect the proper size and number
of ground cables to one of the welding
power source work terminals.

801 882-A

OM-2221 Page 25

4-2. Using Multiple Units: DC Lead Arc, One or More AC Trailing

! Turn Off welding power source and dis-

connect input power before opening
access door.

! High weld output current hazard! Re-

move all metal jewelry, such as rings
and watches, and be careful with tools
near output terminals. High current can
cause severe burns from hot metal if
touched to output terminals and unit is
On. ALWAYS turn Off welding power
sources and disconnect input power
BEFORE making weld output connec­tions.

! Electric shock can kill.

Do not touch live electrical parts.
Turn off welding power sources and disconnect

input power before making any weld output
connections.

See ANSI Z49.1 and OSHA Title 29, Chapter
XVII, Part 1910, Subpart Q (addresses at be­ginning of manual).

Do not handle or come in contact with two live
electrodes at the same time.

! Undersized weld cables can cause fire.

Work cable or electrode cable must be able to
carry the weld output of the individual welding
power source (see Section 3-8).

Do not exceed duty cycle of welding power
sources.

! If there are any questions regarding this

procedure, contact the factory before
connecting units.

To use a DC electrode positive lead arc with
one or more trailing AC arcs, make connec­tions as shown.

When running more than one AC trailing arc,
set up the AC units according to Section 4-4.

DC Output Unit

Connections

To Work

To AC

Output

Electrode #2

To

DC Output Electrode #1

To AC

Output

Electrode #3

First AC Output Unit

Connections

OM-2221 Page 26

To Next AC

Second AC Output Unit

(And Following Units)

To Work To Work

Shielded Cable To
Terminal Strip TE4

Connections

Unit

801 882-A

4-3. Using Multiple Units: Two or More AC Arcs

To AC Output

Electrode #1

First Unit

Connections

To Work To Work

Shielded Cable To
Terminal Strip TE4

Second Unit (And

Following Units)

Connections

To AC Output

Electrode #2

To Next AC Unit

! Turn Off welding power

source and disconnect input
power before opening ac­cess door.

! High weld output current

hazard! Remove all metal
jewelry, such as rings and
watches, and be careful with
tools near output terminals.
High current can cause se­vere burns from hot metal if
touched to output terminals
and unit is On. ALWAYS turn
Off welding power sources
and disconnect input power
BEFORE making weld out­put connections.

! ELectric Shock can kill.

Do not touch live electrical parts.
Turn off welding power sources and

disconnect input power before
making any weld output connec­tions.

See ANSI Z49.1 and OSHA Title
29, Chapter XVII, Part 1910, Sub­part Q (addresses at beginning of
manual).

Do not handle or come in contact
with two live electrodes at the same
time.

! Undersized weld cables can

cause fire.

Work cable or electrode cable must
be able to carry the weld output of
the individual welding power source
(see Section 3-8).

Do not exceed duty cycle of welding
power sources.

! If there are any questions re-

garding this procedure, con­tact the factory before con­necting units.

To use two or more AC arcs with
separate electrodes, make con­nections as shown.

Set up AC output units according to
Section 4-4.

801 882-A

OM-2221 Page 27

4-4. Using AC Arcs Terminal Strip TE4 Connections

Tools Needed:

Phase Shift

Waveform 1

Waveform 2

AC Waveforms

. Use two-conductor (12 to 20 gauge) with uninsulated ground,

shielded cable to make TE4 connections. Connect uninsulated
ground wire to terminal C on TE4.

3/8 in

(10 mm)

3

! Turn Off welding power

source and disconnect input
power before opening ac-

1

cess door.

! DC output units do not re-

quire synchronization with

A

B
C
D
E

AC output units.

! If there are any questions re-

garding this procedure, con­tact the factory before con­necting units.

1 Terminal Strip TE4
This procedure allows the AC out-

put waveforms of two or more units
to have a phase shift. Make con­nections between terminal strip
TE4 on applicable AC output units
as shown in illustration.

. Do not disturb factory connec-

tions to terminal strip TE4.

! Ensure that primary input

power conductors are con­nected to each unit in the
same sequence (L1 to L1, L2
to L2, and L3 to L3). See Sec­tion 3-16 for information on
connecting input power. See
Section 3-17 for information
on testing for proper primary
phase sequence.

2 Lead Being Connected To

1

2

TE4
3 Securing Screw
Strip 3/8 in (10 mm) insulation off

end of lead, insert end into proper
location on TE4, and tighten appli­cable securing screw.

Close and secure access door.

. Connect plug as shown in Sec-

tion 4-5.

A
B
C
D
E

TE4 on first welding

power source

OM-2221 Page 28

Connections from first to second

welding power source:

terminal A to terminal E,

terminal C to terminal C

A
B
C
D
E

TE4 on second welding

power source

Terminal Strip TE4 Connections For Running Multiple AC Arcs

Connections from second to third

welding power source:

terminal A to terminal E,

terminal C to terminal C

A
B
C
D
E

TE4 on third welding

power source

Connections from third to fourth

welding power source:

terminal A to terminal E,

terminal C to terminal C

Repeat same connection sequence

on following welding power sources

Ref. 801 882-A

4-5. Control Board PC1 Connections

2

1

! Turn Off welding power

source and disconnect input

power before following this

procedure.

! If there are any questions re-

garding this procedure, con-

tact the factory before con-

necting units.

Remove top cover.
1 Front Panel
2 Control Board PC1
PC1 is mounted on inside of control

panel.
3 Receptacle RC4
PC1 arrives from the factory with a

66/34 plug.
Plugs are labeled accordingly.

. Always keep disconnected

plug for future use.

Reinstall circuit card cover and top
cover.

2

3

PC1 Viewed From Rear Of Unit

Tools Needed:

3/8 in

Ref. 801 982-A

OM-2221 Page 29

SECTION 5 − OPERATION

5-1. Front Panel Controls (Non-CE Models)

1 Output Control Switch
For weld output, place switch in On position.

For remote control of output, make connec­tions to terminal strip TE3 or Remote 14 re­ceptacle (see Section 3-10) and place switch
in Remote position.

2 A/V (Amperage/Voltage) Control Switch
For front panel control, place switch in Panel

position and use the A/V Adjust control.

! Turn Off power before connecting re-

mote device.

For remote control, connect remote device to
terminal strip TE3 or Remote 14 receptacle,
and place switch in Remote position. Remote
control provides full range of unit output re­gardless of A/V Adjust control setting

3 Pilot Light
4 Power Push Button Switch

. The fan motor is thermostatically

controlled and only runs when cooling is
needed.

5 High Temperature Shutdown Light
Lights if welding power source overheats.

12

6

6 A/V (Amperage/Voltage) Adjustment

Control

Use control to select weld voltage or amper­age. Control may be adjusted while welding.
Numbers on scale are for reference only.

7 CC/CV Switch (Mounted Inside Access

Area)

! Turn Off welding power source before

opening access door to change switch
position.

Place switch in desired position.

3

4

5

OM-2221 Page 30

CC

CV

7

Ref. 175 086 / Ref. 801 882-A

5-2. Front Panel Controls (CE Models)

1 Output Control Switch
For weld output, place switch in On position.

For remote control of output, make connec­tions to terminal strip TE3 or Remote 14 re­ceptacle (see Section 3-10) and place switch
in Remote position.

2 A/V (Amperage/Voltage) Control Switch
For front panel control, place switch in Panel

position and use the A/V Adjust control.

! Turn Off power before connecting re-

mote device.

For remote control, connect remote device to
terminal strip TE3 or Remote 14 receptacle,
and place switch in Remote position. Remote
control provides full range of unit output re­gardless of A/V Adjust control setting

3 Pilot Light
4 Power Push Button Switch

. The fan motor is thermostatically

controlled and only runs when cooling is
needed.

5 High Temperature Shutdown Light
Lights if welding power source overheats.

1

2

6

6 A/V (Amperage/Voltage) Adjustment

Control

Use control to select weld voltage or amper­age. Control may be adjusted while welding.
Numbers on scale are for reference only.

7 CC/CV Switch (Mounted Inside Access

Area)

! Turn Off welding power source before

opening access door to change switch
position.

Place switch in desired position.

3

4

5

CC

CV

7

Ref. 175 086 / Ref. 801 882-A

OM-2221 Page 31

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING

6-1. Routine Maintenance

Every
3
Months

Every
3
Months

Every
3
Months

Every
6
Months

! Disconnect input power

before maintaining.

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

nl Labels l Cracked Parts

nΔ lCables And Cords

~:Weld Terminals

Δ l Cracked Cables

. Maintain more often

during severe conditions.

~:Blow out inside

6-2. Fuses F1 And F2

1

2

! Turn Off welding power

source and disconnect input

power before checking fuse.

Fuses F1 and F2 protect the 115
volt AC winding of transformer T2.
If fuse F1 or F2 opens, the welding
power source shuts down.

Remove top cover from unit to ac­cess fuses.

1 Fuse F1
Check F1 and replace if needed,

using a fuse of the same rating.
2 Fuse F2
Check F2 and replace if needed,

using a fuse of the same rating.
Use proper tool when removing

fuses.
Reinstall top cover.

OM-2221 Page 32

Rear of Unit

Tools Needed:

3/8 in

Ref. 801 883-B

6-3. Access Area Supplementary Protectors

! Turn Off welding power

source and disconnect input

power before checking cir-

cuit breakers.

1 Supplementary Protector CB2
CB2 protects the 24 VAC portion of

terminal strip TE3 and the Remote
14 receptacle.

2 Supplementary Protector CB3
CB3 protects the 42 VAC portion of

1

2

CB2

CB3

terminal strip TE3.
Press button to reset breaker.

Ref. 175 086 / 801 882-A

6-4. Troubleshooting

Trouble Remedy

No weld output; unit completely in­operative.

No weld output; pilot light On. Check, repair, or replace remote control.

Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-8).

No 115 volts AC output at duplex
receptacle, terminal strip TE3, and Re­mote 14 receptacle.

Place line disconnect switch in On position (see Section 3-16).

Check fuses F1 and F2 and replace if necessary (see Section 6-2).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-16).

Check for proper input power connections (see Section 3-16).

Unit overheated. Allow unit to cool with fan On (see Section 3-2).

Have Factory Authorized Service Agent check control board PC1.

Clean and tighten all weld connections.

When using multiple units, make sure all units connected with terminal strip TE4 are turned on.

Have Factory Authorized Service Agent check control board PC1.

Reset supplementary protector CB1 (see Section 3-13).

No 230 volts AC output at duplex re­ceptacle.

No 24 volts AC output at terminal strip
TE3 and Remote 14 receptacle.

No 42 volts AC output at terminal strip
TE3.

Reset supplementary protector CB4 (see Section 3-14).

Reset supplementary protector CB2 (see Section 6-3).

Reset supplementary protector CB3 (see Section 6-3).

OM-2221 Page 33

SECTION 7 − ELECTRICAL DIAGRAMS

OM-2221 Page 34

224 360-A

Figure 7.1. Circuit Diagram For 460 And 575 VAC Input Models

Figure 7.2. Circuit Diagram For 400 VAC Input Models

224 361-A

OM-2221 Page 35

SECTION 8 − PARTS LIST

14

33

11

12

4

3

2

1

32

6

5

13

18

15

16

17

19

21

22

OM-2221 Page 36

25

26

1

24

30

27

29

28

31

27

23

5

. Hardware is common and

not available unless listed.

801 981-B

Figure 8-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-1. Main Assembly

1 071 624 Panel, Side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +070 555 Cover, Top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 217 136 Label,Warning Electric Shock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 217 862 Label,Warning Electric Shock And AC/DC Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 184 340 Channel, Upright 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 188 403 Bracket, Mtg Lem 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 F1,F2 *012 639 Fuse, Crtg 6A 600 V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 070 404 Fuse, Holder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 W 099 044 Contactor, Size 3-1/2 3P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W1,2 213 446 Interlock, Cntor No. Size 3-1/2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C1-3 219 496 Capacitor (All Models) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 184 349 Bracket, Mtg Contactor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 HD1 148 417 Transducer, Current 1000A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 130 204 Connector & Socket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 TE2 213 419 Terminal Assembly, Pwr Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 184 359 Bracket, Mtg Terminal Assembly 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Fig 8-3 Rear Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 217 860 Label,Warning Electric Shock And Input Pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 Z1 184 350 Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 T1 184 406 Transformer, Pwr Main (460 Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 T1 188 222 Transformer, Pwr Main (575 Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 T1 185 360 Transformer, Pwr Main (400 50/60Hz Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP2 216 600 Thermostat, NC Open 150° C W/Insulator Leads & Terms 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP1 168 891 Thermostat, NC In Trans. 80° C Fan On Demand 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 184 344 Stop, Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

026 627 Gasket, Lift Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 T2 094 237 Transformer, KVA 1/2 115-230/460 (460 Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 T2 096 145 Transformer, KVA 1/2 115-230/575 (575 Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 T2 185 359 Transformer, KVA 1/2 115-220/400 (400 50/60Hz Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

21 184 342 Lift, Eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 184 341 Bar, Cross Lift Eye 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 184 345 Bracket, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 SR1 213 441 Rectifier, Scr Main (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 026 947 Stand-Off, Insul .250-20 X 1.000 Lg 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 185 206 Strip, Mtg Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 196 496 Clamp, Thyristor Rectifier 4.750 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 SCR1-6 148 091 Thyristor, Scr 865 A 300 V 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 185 207 Strip, Spacing Heat Sink 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

082 852 Bus Bar, Output Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 C11-16/. . .

R11-16 185 183 Capacitor/Resistor 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP3, 4, 5. . . . . .

6, 7, 8 192 732 Thermostat, NC Open 203° F In Sr1 Overload 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP9, 10,. . . . . .

11, 12, 13, 14 168 900 Thermostat, NC Open 125° F Close 105° F No Flange Fasto 6. . . . . . . . . . . . . . . . .

31 191 248 Heat Sink, Rectifier Snowflake 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 184 343 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 Fig 8-2 Front Panel Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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-2221 Page 37

22

15

21

14

20

10

19

18

38

17

23

24

26

25

16

15

13

12

11

30

9

8

7

6

27

29

5

28

39

5

4

3

33

34

35

2

1

36

37

39

32

. Hardware is common and

not available unless listed.

31

801 982-D

Figure 8-2. Front Panel Assembly

OM-2221 Page 38

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-2. Front Panel Assembly (Figure 8-1 Item 32)

1 038 805 Cover, Receptacle Weatherproof 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Nameplate, (Order By Model And Serial Number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 +187 759 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 RC1 604 176 Receptacle, Str Dx Grd 2P3W 15A 125V (460 & 575 Models) 1. . . . . . . . . . . . . . . . . . . . .

4 RC1 176 355 Receptacle, Str 2P3W 16A 220V (400 50/60Hz Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CB1-3 093 995 SUPPLEMENTARY PROTECTOR, Man Reset 1P 15A 250VAC Fric. . . . . . . . . .

(460 & 575 Models) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CB1-4 093 995 SUPPLEMENTARY PROTECTOR, Man Reset 1P 15A 250VAC Fric. . . . . . . . . .

(400 50/60Hz Model) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S2 011 611 Switch, Tgl DPDT 15A 125VAC On-None-On Spd Term Chr 1. . . . . . . . . . . . . . . . . . . . . . . . . .

7 S1 011 609 Switch, Tglspdt 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 R5 030 109 Potentiometer, Cp Std Slot 1/T 2W 5K Linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PB1 011 636 Switch, Pushbutton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PC1 222 424 Circuit Card, Control (460 & 575 Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PC1 227 718 Circuit Card, Control (400 50/60Hz Model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 163 467 Connector & Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG12 152 249 Connector & Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 158 720 Connector & Sockets 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CR1 039 498 Relay, Encl 120 VAC 3PDT 10A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 C9,10 130 710 Capacitor Assembly 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 R3,4 136 076 Resistor, Ww Fxd 30W 200 Ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 059 567 Terminal, Pwr Output (Consisting Of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 601 841 Nut, Brs Hex Jam .625-11 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 038 032 Bus Bar, Neg And Pos Sec 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208 935 Terminal, Hammer On 3/0 − 4/0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 601 842 Nut, Brs Hex Full .625-11 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 059 566 Terminal Board, Pwr Output 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 038 909 Stud, Brs .625-11 X 3.000 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 602 249 Washer, Flat Stl Sae .625 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 602 219 Washer, Lock Stl External Tooth .625 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 059 983 Bus Bar, Jumper Secondary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 188 514 Bracket, Mtg Term Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 110 375 Stand-Off, Support PC Card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 PC2 148 030 Circuit Card, Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 RC7 134 735 Connector, Circ Ms/Cpc 14 Skt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 S3 011 611 Switch, Tgl DPDT 15A 125 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 TE4 192 357 Block, Term 40A 5P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 TE3 188 719 Block, Term 40A 12P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 098 691 Stand-Off, No. 6-32 X .500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 605 583 Catch, Spr Loaded Door 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 217 861 Label, Warning Electric Shock Can Kill Etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 027 631 Housing, Light Ind 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 PL1,2 027 629 Bulb, Incand 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 182 704 Lens, Light Ind White 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 176 246 Lens, Light Ind Amber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 097 924 Knob, Pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 209 319 Kit, Variable Balance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 117 860 Blank, Snap-In Nyl .187 Mtg Hole Black 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+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-2221 Page 39

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-3. Rear Panel Assembly (Figure 8-1 Item 15)

1 CR2 059 266 Relay, Encl 120 VAC DPDT 10A/120 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 222 352 Windtunnel, 20In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 R1,2 097 459 Resistor, WW Fxd 375W 20 Ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 222 347 Blade, Fan 20.000 3Wg 13Deg .500 Bore Cw Al 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 +070 558 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 183 167 Connector, Clamp Cable 2.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 102 207 Plate, Adapter Power Cord 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 FM 032 605 Motor, Cap Perm Sp 1/4Hp 230 VAC 1625RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CR3 188 184 Relay, Encl 24/120VAC DPDT 5A/120VAC 9Pin Flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

3

4

2

1

7

5

6

8

. Hardware is common and

9

Figure 8-3. Rear Panel Assembly

+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-2221 Page 40

not available unless listed.

801 983-A

Warranty Questions?

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

Your distributor also gives
you ...

Service

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

Support

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

Effective January 1, 2008

(Equipment with a serial number preface of LJ 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
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

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

3. 1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* 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.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts
* MIG Guns and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* 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.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend
models.)

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 2008-01

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]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

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.

PRINTED IN USA © 2008 Miller Electric Mfg. Co.2008−01