OM-217 655E 200701

Processes
Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Arc Welding Power Source

CST 280 And

CST 280 VRD International

Visit our website at File: Stick (SMAW)

www.MillerWelds.com

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 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 dont have time to do
it any other way.
Thats 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 couldnt 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. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
Weve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual 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 4/05

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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utiliss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3. Stick (SMAW) Volt-Ampere Curves CST 280 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-4. TIG (GTAW) Volt-Ampere Curve CST 280 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-5. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-6. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-7. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-8. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-9. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-10. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-12. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-13. Selecting 400 - 575 Volts AC Three Phase Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-14. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-15. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-2. Process Select Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-3. Stick Start Procedure Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-4. Lift-ArcE Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-5. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-7. Fan-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-8. Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 6 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPTIONS AND ACCESSORIES
WARRANTY

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 SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
 Warning: Protect yourself and others from injury read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
 Marks a special safety message.
 Means Note; not safety related.
1-2. Arc Welding Hazards
 The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
 Only qualified persons should install, operate, maintain, and
repair this unit.
 During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
 Do not touch live electrical parts.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
 Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on
unit.
 Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able 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 volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
 Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
 Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
 Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
 When making input connections, attach proper grounding conduc-
tor first double-check connections.
 Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
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som _3/05
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly
with a separate cable.
 Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
 Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
 Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
 Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
 Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
 Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturers instructions for metals, consumables,
coatings, cleaners, and degreasers.
 Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
 Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
 Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
OM-217 655 Page 1
 ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
 Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
 Wear approved safety glasses with side shields under your
helmet.
 Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
 Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
 Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
 Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
 Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
 Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
 Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
 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 can injure eyes.
 Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
 Wear approved safety glasses with side
shields even under your welding helmet.
OM-217 655 Page 2
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BUILDUP OF GAS can injure or kill.
 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
 Do not touch hot parts bare handed.
 Allow cooling period before working on gun or
torch.
 To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MAGNETIC FIELDS can affect pacemakers.
 Pacemaker wearers keep away.
 Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
 Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
 Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
 Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
 Turn face away from valve outlet when opening cylinder valve.
 Keep protective cap in place over valve except when cylinder is in
use or connected for use.
 Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
 Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
 1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
 Do not install or place unit on, over, or near
combustible surfaces.
 Do not install unit near flammables.
 Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
 Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
 Use equipment of adequate capacity to lift and
support unit.
 If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before
starting to weld again.
 Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
 Put on grounded wrist strap BEFORE handling
boards or parts.
 Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
 Keep away from moving parts.
 Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
 Do not press gun trigger until instructed to do
so.
 Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
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MOVING PARTS can cause injury.
 Keep away from moving parts such as fans.
 Keep all doors, panels, covers, and guards
closed and securely in place.
 Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
 Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
READ INSTRUCTIONS.
 Read Owners Manual before using or servic-
ing unit.
 Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
 High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
 Have only qualified persons familiar with
electronic equipment perform this installation.
 The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
 If notified by the FCC about interference, stop using the
equipment at once.
 Have the installation regularly checked and maintained.
 Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
 Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
 Be sure all equipment in the welding area is
electromagnetically compatible.
 To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
 Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
 Be sure this welding machine is installed and grounded
according to this manual.
 If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
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.
OM-217 655 Page 3
 1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting 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 Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (phone: 6177703000, website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-
site: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
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 electro-
magnetic 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
committees judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-217 655 Page 4
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Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
8004636727 or in Toronto 4167474044, website: www.csain-
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 100368002 (phone: 2126424900,
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, 1 Battery March Park, Quincy, MA 022699101 (phone:
6177703000,website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Officesphone for Region 5, Chicago, is
3123532220,website: www.osha.gov).
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
 SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
 Avertissement : se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.
2-1. Symboles utiliss
Symbole graphique davertissement ! Attention ! Cette pro-
cdure comporte des risques possibles ! Les dangers ven-
tuels sont reprsents par les symboles graphiques joints.
 Indique un message de scurit particulier
 Signifie NOTE ; nest pas relatif la scurit.
2-2. Dangers relatifs au soudage larc
 Les symboles reprsents ci-dessous sont utiliss dans ce manuel
pour attirer lattention et identifier les dangers possibles. En
prsence de lun de ces symboles, prendre garde et suivre les
instructions affrentes pour viter tout risque. Les instructions en
matire de scurit indiques ci-dessous ne constituent quun
sommaire des instructions de scurit plus compltes fournies
dans les normes de scurit numres dans la Section 2-5. Lire et
observer toutes les normes de scurit.
 Seul un personnel qualifi est autoris installer, faire fonction-
ner, entretenir et rparer cet appareil.
 Pendant le fonctionnement, maintenir distance toutes les per-
sonnes, notamment les enfants de lappareil.
UNE DCHARGE LECTRIQUE peut
entraner la mort.
Le contact dorganes lectriques sous tension peut
provoquer des accidents mortels ou des brlures
graves. Le circuit de llectrode et de la pice est
sous tension lorsque le courant est dlivr la
sortie. Le circuit dalimentation et les circuits internes de la machine
sont galement sous tension lorsque lalimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc de
commande du rouleau et toutes les parties mtalliques en contact
avec le fil sont sous tension lectrique. Un quipement install ou mis
la terre de manire incorrecte ou impropre constitue un danger.
 Ne pas toucher aux pices lectriques sous tension.
 Porter des gants isolants et des vtements de protection secs et sans
trous.
 Sisoler de la pice couper et du sol en utilisant des housses ou des
tapis assez grands afin dviter tout contact physique avec la pice
couper ou le sol.
 Ne pas se servir de source lectrique courant lectrique dans les zo-
nes humides, dans les endroits confins ou l o on risque de tomber.
 Se servir dune source lectrique courant lectrique UNIQUEMENT si
le procd de soudage le demande.
 Si lutilisation dune source lectrique courant lectrique savre n-
cessaire, se servir de la fonction de tlcommande si lappareil en est
quip.
 Dautres consignes de scurit sont ncessaires dans les conditions
suivantes : risques lectriques dans un environnement humide ou si lon
porte des vtements mouills ; sur des structures mtalliques telles que
sols, grilles ou chafaudages ; en position coince comme assise, ge-
noux ou couche ; ou sil y a un risque lev de contact invitable ou
accidentel avec la pice souder ou le sol. Dans ces conditions, utiliser
les quipements suivants, dans lordre indiqu : 1) un poste souder DC
tension constante ( fil), 2) un poste souder DC manuel (lectrode)
ou 3) un poste souder AC tension vide rduite. Dans la plupart des
situations, lutilisation dun poste souder DC fil tension constante
est recommande. En outre, ne pas travailler seul !
 Couper lalimentation ou arrter le moteur avant de procder
linstallation, la rparation ou lentretien de lappareil. Dverrouiller
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
scurit).
 Installer le poste correctement et le mettre la terre convenablement
selon les consignes du manuel de loprateur et les normes nationales,
provinciales et locales.
 Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurer
que le fil de terre du cordon dalimentation est bien raccord la borne
de terre du sectionneur ou que la fiche du cordon est raccorde une
prise correctement mise la terre.
 En effectuant les raccordements dentre, fixer dabord le conducteur
de mise la terre appropri et contre-vrifier les connexions.
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som _3/05
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
dLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions affrentes
ci-dessous concernant les mesures prendre pour supprimer
les dangers.
 Vrifier frquemment le cordon dalimentation afin de sassurer quil
nest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nu
peut entraner la mort.
 Lquipement doit tre hors tension lorsquil nest pas utilis.
 Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante
ou mal pisss.
 Ne pas enrouler les cbles autour du corps.
 Si la pice soude doit tre mise la terre, le faire directement avec un
cble distinct.
 Ne pas toucher llectrode quand on est en contact avec la pice, la terre
ou une lectrode provenant dune autre machine.
 Ne pas toucher des porte lectrodes connects deux machines en
mme temps cause de la prsence dune tension vide double.
 Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-
champ les pices endommages. Entretenir lappareil conformment
ce manuel.
 Porter un harnais de scurit si lon doit travailler au-dessus du sol.
 Sassurer que tous les panneaux et couvercles sont correctement en
place.
 Fixer le cble de retour de faon obtenir un bon contact mtal-mtal
avec la pice souder ou la table de travail, le plus prs possible de la
soudure.
 Isoler la pince de masse quand pas mis la pice pour viter le contact
avec tout objet mtallique.
 Ne pas raccorder plus dune lectrode ou plus dun cble de masse
une mme borne de sortie de soudage.
Il reste une TENSION DC NON NGLIGEABLE dans
les sources de soudage onduleur quand on a coup
lalimentation.
 Arrter les convertisseurs, dbrancher le courant lectrique et
dcharger les condensateurs dalimentation selon les instructions indi-
ques dans la partie Entretien avant de toucher les pices.
LES FUMES ET LES GAZ peuvent
tre dangereux.
Le soudage gnre des fumes et des gaz. Leur
inhalation peut tre dangereuse pour la sant.
 Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces va-
peurs.
 lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau de
larc pour lvacuation des fumes et des gaz de soudage.
 Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approu-
v.
 Lire et comprendre les spcifications de scurit des matriaux (MSDS) et
les instructions du fabricant concernant les mtaux, les consommables, les
revtements, les nettoyants et les dgraisseurs.
 Travailler dans un espace ferm seulement sil est bien ventil ou en
portant un respirateur alimentation dair. Demander toujours un sur-
veillant dment form de se tenir proximit. Des fumes et des gaz de
soudage peuvent dplacer lair et abaisser le niveau doxygne provo-
quant des blessures ou des accidents mortels. Sassurer que lair de
respiration ne prsente aucun danger.
 Ne pas souder dans des endroits situs proximit doprations de d-
graissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de
larc peuvent ragir en prsence de vapeurs et former des gaz haute-
ment toxiques et irritants.
 Ne pas souder des mtaux munis dun revtement, tels que lacier gal-
vanis, plaqu en plomb ou au cadmium moins que le revtement nait
t enlev dans la zone de soudure, que lendroit soit bien ventil et en
portant un respirateur alimentation dair. Les revtements et tous les
mtaux renfermant ces lments peuvent dgager des fumes toxi-
ques en cas de soudage.
OM-217 655 Page 5
 LES RAYONS DARC peuvent entra-
ner des brlures aux yeux et la peau.
Le rayonnement de larc du procd de soudage
gnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-
quer des brlures dans les yeux et sur la peau.
Des tincelles sont projetes pendant le soudage.
 Porter un casque de soudage approuv muni de verres filtrants ap-
propri pour protger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 numr dans les normes de scurit).
 Porter des lunettes de scurit avec crans latraux mme sous vo-
tre casque.
 Avoir recours des crans protecteurs ou des rideaux pour
protger les autres contre les rayonnements les blouissements et
les tincelles ; prvenir toute personne sur les lieux de ne pas
regarder larc.
 Porter des vtements confectionns avec des matires rsistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectu sur des conteneurs ferms tels
que des rservoirs, tambours ou des conduites peut
provoquer leur clatement. Des tincelles peuvent
tre projetes de larc de soudure. La projection
dtincelles, des pices chaudes et des quipements chauds peuvent
provoquer des incendies et des brlures. Le contact accidentel de
llectrode avec des objets mtalliques peut provoquer des tincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vrifier et sassurer que lendroit ne prsente pas de
danger.
 Dplacer toutes les substances inflammables une distance de
10,7 m de larc de soudage. En cas dimpossibilit, les recouvrir soi-
gneusement avec des protections homologues.
 Ne pas souder dans un endroit o des tincelles peuvent tomber sur
des substances inflammables.
 Se protger, ainsi que toute autre personne travaillant sur les lieux,
contre les tincelles et le mtal chaud.
 Des tincelles et des matriaux chauds du soudage peuvent
facilement passer dans dautres zones en traversant de petites
fissures et des ouvertures.
 Afin dliminer tout risque de feu, tre vigilant et garder toujours un
extincteur la porte de main.
 Le soudage effectu sur un plafond, plancher, paroi ou sparation
peut dclencher un incendie de lautre ct.
 Ne pas effectuer le soudage sur des conteneurs ferms tels que des
rservoirs, tambours, ou conduites, moins quils naient t prpa-
rs correctement conformment AWS F4.1 (voir les normes de
scurit).
 Brancher le cble de masse sur la pice le plus prs possible de la
zone de soudage pour viter le transport du courant sur une longue
distance par des chemins inconnus ventuels en provoquant des
risques dlectrocution, dtincelles et dincendie.  Placer les bouteilles debout en les fixant dans un support sta-
 Ne pas utiliser le poste de soudage pour dgeler des conduites
geles.
 En cas de non-utilisation, enlever la baguette dlectrode du porte-
lectrode ou couper le fil la pointe de contact.
 Porter des vtements de protection exempts dhuile tels que des
gants en cuir, une veste rsistante, des pantalons sans revers, des
bottes et un casque.
 Avant de souder, retirer toute substance combustible de ses poches
telles quun allumeur au butane ou des allumettes.
 Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prvoir un dtecteur dincendie et un ex-
tincteur proximit.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
 Le soudage, lcaillement, le passage de la
pice la brosse en fil de fer, et le meulage
gnrent des tincelles et des particules
mtalliques volantes. Pendant la priode de
refroidissement des soudures, elles risquent
de projeter du laitier.
 Porter des lunettes de scurit avec crans latraux ou un cran
facial.
OM-217 655 Page 6
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LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou mme la mort.
 Fermer lalimentation du gaz protecteur en cas
de non-utilisation.
 Veiller toujours bien arer les espaces confi-
ns ou se servir dun respirateur dadduction
dair homologu.
DES PICES CHAUDES peuvent
provoquer des brlures graves.
 Ne pas toucher des parties chaudes mains
nues.
 Prvoir une priode de refroidissement avant
dutiliser le pistolet ou la torche.
 Ne pas toucher aux pices chaudes, utiliser les outils recom-
mands et porter des gants de soudage et des vtements pais
pour viter les brlures.
LES CHAMPS MAGNTIQUES peuvent
affecter les stimulateurs cardiaques.
 Porteurs de stimulateur cardiaque, rester
distance.
 Les porteurs dun stimulateur cardiaque doi-
vent dabord consulter leur mdecin avant de
sapprocher des oprations de soudage larc,
de gougeage ou de soudage par points.
LE BRUIT peut endommager loue.
Le bruit des processus et des quipements peut
affecter loue.
 Porter des protections approuves pour les
oreilles si le niveau sonore est trop lev.
LES BOUTEILLES peuvent exploser
si elles sont endommages.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
ge, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procd de soudage,
les manipuler avec prcaution.
 Protger les bouteilles de gaz comprim dune chaleur excessi-
ve, des chocs mcaniques, des dommages physiques, du lai-
tier, des flammes ouvertes, des tincelles et des arcs.
tionnaire ou dans un porte-bouteilles pour les empcher de tom-
ber ou de se renverser.
 Tenir les bouteilles loignes des circuits de soudage ou autres
circuits lectriques.
 Ne jamais placer une torche de soudage sur une bouteille gaz.
 Une lectrode de soudage ne doit jamais entrer en contact avec
une bouteille.
 Ne jamais souder une bouteille pressurise risque dexplosion.
 Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,
tuyaux et raccords convenables pour cette application spcifi-
que ; les maintenir ainsi que les lments associs en bon tat.
 Dtourner votre visage du dtendeur-rgulateur lorsque vous
ouvrez la soupape de la bouteille.
 Le couvercle du dtendeur doit toujours tre en place, sauf lors-
que la bouteille est utilise ou quelle est relie pour usage ult-
rieur.
 Utiliser les quipements corrects, les bonnes procdures et suf-
fisamment de personnes pour soulever et dplacer les bouteil-
les.
 Lire et suivre les instructions sur les bouteilles de gaz comprim,
lquipement connexe et le dpliant P-1 de la CGA (Compressed
Gas Association) mentionn dans les principales normes de scuri-
t.
 2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance
Risque DINCENDIE OU DEXPLO-
SION.
 Ne pas placer lappareil sur, au-dessus ou
proximit de surfaces inflammables.
 Ne pas installer lappareil proximit de
produits inflammables.
 Ne pas surcharger linstallation lectrique sassurer que
lalimentation est correctement dimensionne et protge avant
de mettre lappareil en service.
LA CHUTE DE LAPPAREIL peut
blesser.
 Utiliser lanneau de levage uniquement pour
soulever lappareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
 Utiliser un quipement de levage de capacit
suffisante pour lever lappareil.
 En utilisant des fourches de levage pour dplacer lunit, sassu-
rer que les fourches sont suffisamment longues pour dpasser
du ct oppos de lappareil.
LEMPLOI EXCESSIF peut SUR-
CHAUFFER LQUIPEMENT.
 Prvoir une priode de refroidissement ;
respecter le cycle opratoire nominal.
 Rduire le courant ou le facteur de marche
avant de poursuivre le soudage.
 Ne pas obstruer les passages dair du poste.
LES CHARGES LECTROSTATIQUES
peuvent endommager les circuits
imprims.
 tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pices.
 Utiliser des pochettes et des botes antistati-
ques pour stocker, dplacer ou expdier des
cartes PC.
DES ORGANES MOBILES peuvent
provoquer des blessures.
 Ne pas sapprocher des organes mobiles.
 Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
 Ne pas appuyer sur la gchette avant den
avoir reu linstruction.
 Ne pas diriger le pistolet vers soi, dautres
personnes ou toute pice mcanique en enga-
geant le fil de soudage.
2-4. Proposition californienne 65 Avertissements
 Les quipements de soudage et de coupage produisent des
fumes et des gaz qui contiennent des produits chimiques dont
ltat de Californie reconnat quils provoquent des malformations
congnitales et, dans certains cas, des cancers. (Code de sant et
de scurit de Californie, chapitre 25249.5 et suivants)
 Les batteries, les bornes et autres accessoires contiennent du
plomb et des composs base de plomb, produits chimiques
dont ltat de Californie reconnat quils provoquent des can-
cers et des malformations congnitales ou autres problmes de
procration. Se laver les mains aprs manipulation.
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DES ORGANES MOBILES peuvent
provoquer des blessures.
 Sabstenir de toucher des organes mobiles tels
que des ventilateurs.
 Maintenir ferms et verrouills les portes,
panneaux, recouvrements et dispositifs de
protection.
 Seules des personnes qualifies sont autorises enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour lentretien.
 Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand lentretien est termin et avant de rebrancher
lalimentation lectrique.
LIRE LES INSTRUCTIONS.
 Lire le manuel dutilisation avant dutiliser ou
dintervenir sur lappareil.
 Utiliser uniquement des pices de rechange
Miller/Hobart.
LE RAYONNEMENT HAUTE
FRQUENCE (HF) risque de provoquer
des interfrences.
 Le rayonnement haute frquence (HF) peut
provoquer des interfrences avec les quipe-
ments de radio-navigation et de communica-
tion, les services de scurit et les ordinateurs.
 Demander seulement des personnes qualifies familiarises
avec des quipements lectroniques de faire fonctionner linstal-
lation.
 Lutilisateur est tenu de faire corriger rapidement par un lectri-
cien qualifi les interfrences rsultant de linstallation.
 Si le FCC signale des interfrences, arrter immdiatement
lappareil.
 Effectuer rgulirement le contrle et lentretien de linstallation.
 Maintenir soigneusement ferms les portes et les panneaux des
sources de haute frquence, maintenir les clateurs une
distance correcte et utiliser une terre et un blindage pour rduire
les interfrences ventuelles.
LE SOUDAGE LARC risque de
provoquer des interfrences.
 Lnergie lectromagntique peut gner le
fonctionnement dappareils lectroniques
comme des ordinateurs et des robots.
 Veiller ce que tout lquipement de la zone de
soudage soit compatible lectromagntiquement.
 Pour rduire la possibilit dinterfrence, maintenir les cbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
 Veiller souder une distance de 100 mtres de tout quipe-
ment lectronique sensible.
 Veiller ce que ce poste de soudage soit pos et mis la terre
conformment ce mode demploi.
 En cas dinterfrences aprs avoir pris les mesures prcden-
tes, il incombe lutilisateur de prendre des mesures suppl-
mentaires telles que le dplacement du poste, lutilisation de
cbles blinds, lutilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
Pour les moteurs essence :
 Les gaz dchappement des moteurs contiennent des produits
chimiques dont ltat de Californie reconnat quils provoquent
des cancers et des malformations congnitales ou autres pro-
blmes de procration.
Pour les moteurs diesel :
 Les gaz dchappement des moteurs diesel et certains de leurs
composants sont reconnus par ltat de Californie comme
provoquant des cancers et des malformations congnitales ou au-
tres problmes de procration.
OM-217 655 Page 7
 2-5. Principales normes de scurit
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (tlphone : 1-877-413-5184, site In-
ternet : www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (tlphone : 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, 1 Battery March Park, Quincy, MA
02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (tlphone : 703-412-0900, site Internet
: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale
2-6. Information EMF
Considrations sur le soudage et les effets de basse frquence et des
champs magntiques et lectriques.
Le courant de soudage, pendant son passage dans les cbles de souda-
ge, causera des champs lectromagntiques. Il y a eu et il y a encore un
certain souci propos de tels champs. Cependant, aprs avoir examin
plus de 500 tudes qui ont t faites pendant une priode de recherche
de 17 ans, un comit spcial ruban bleu du National Research Council a
conclu : Laccumulation de preuves, suivant le jugement du comit, na
pas dmontr que lexposition aux champs magntiques et champs lec-
triques haute frquence reprsente un risque la sant humaine .
Toutefois, des tudes sont toujours en cours et les preuves continuent
tre examines. En attendant que les conclusions finales de la recherche
soient tablies, il vous serait souhaitable de rduire votre exposition aux
champs lectromagntiques pendant le soudage ou le coupage.
Pour rduire les champs magntiques sur le poste de travail, appliquer
les procdures suivantes :
OM-217 655 Page 8
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Boulevard, Rexdale, Ontario, Canada M9W 1R3 (tlphone :
800-463-6727 ou Toronto 416-747-4044, site Internet :
www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (tlphone : 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, 1 Battery March Park, Quincy, MA 02269-9101 (tlphone :
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, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
bureaux rgionauxle tlphone de la rgion 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
1. Maintenir les cbles ensemble en les tordant ou en les enveloppant.
2. Disposer les cbles dun ct et distance de loprateur.
3. Ne pas courber pas et ne pas entourer pas les cbles autour de
votre corps.
4. Garder le poste de soudage et les cbles le plus loin possible de
vous.
5. Connecter la pince sur la pice aussi prs que possible de la sou-
dure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur mdecin
avant de souder ou dapprocher des oprations de soudage. Si le mde-
cin approuve, il est recommand de suivre les procdures prcdentes.
 SECTION 3 INSTALLATION
3-1. Specifications
A. 220-230/460-575 Volts Model*
Welding Input Rated Welding Maximum Amperes Input At Rated
Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
220 230 460 575
280 A @
31.2 VDC,
35.0 34.2 17.8 14.7 14.6 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.3 22.5 11.7 9.7 9.6 6.4
100 % (343 mm)
Stick Duty Cycle 7-1/2
W: 7 1/2 in 41 lb
77 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 10.1 6.6 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
32.7 32.0 n/a n/a 7.3 4.6
100 %
Duty Cycle
*Unit can be ordered with Dinse or Tweco weld output receptacles.

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

Welding Input Rated Welding Maximum Amperes Input At Rated
Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
208 230 400 460
280 A @
31.2 VDC,
36.0 34.0 19.8 17.5 14.0 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.5 22.8 13.5 12.7 10.2 6.9
100 % (343 mm)
Stick Duty Cycle W: 7
7-1/2
1/2 in 41 lb
67 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 9.9 6.5 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
35.0 32.9 n/a n/a 7.6 4.8
100 %
Duty Cycle
*Unit can be ordered with Dinse or Tweco weld output receptacles.

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

Welding Input Rated Welding Maximum Amperes Input At Rated

Mode Power Output Amperage Open-Circuit Load Output, 50/60 Hz Net
KVA KW Dimensions
Range Voltage Weight
208 230 400 460
280 A @
31.2 VDC,
36.0 34.0 19.8 17.5 14.0 10.2
35 % Duty
Cycle
3-Phase 5-280 A
200 A @
28 VDC, H: 13-1/2 in
23.5 22.8 13.5 12.7 10.2 6.9
100 % (343 mm)
Stick Duty Cycle 7-1/2
W: 7 1/2 in 41 lb
30 VDC
(SMAW) 200 A @ (191 mm) (18.6 kg)
28 VDC, D: 18 in (457
43.9 43.0 n/a n/a 9.9 6.5 mm)
50 % Duty
Cycle
1-Phase 5-200 A
150 A @
26 VDC,
35.0 32.9 n/a n/a 7.6 4.8
100 %
Duty Cycle
*Unit can be ordered with Dinse or Tweco weld output receptacles.

3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops, and
cooling fan runs. Wait fifteen
minutes for unit to cool. Reduce
amperage or duty cycle before
welding.
 Exceeding duty cycle can
damage unit and void
warranty.

221 587-A

200 A @ 50% Duty Cycle For Single Phase Operation 280 A @ 35% Duty Cycle For 3 Phase Operation

5 Minutes Welding 5 Minutes Resting 3-1/2 Minutes Welding 6-1/2 Minutes Resting

Overheating
0 A or V

15
OR
Minutes Reduce Duty Cycle

OM-217 655 Page 10

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 3-3. Stick (SMAW) Volt-Ampere Curves CST 280 Model
xx10 Stick VA Curves Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
100 shown.

90

80

70

60
DC VOLTS

575V Primary
50

40
208V Primary
30

20
280A
STIFF
10
30A SOFT 30A STIFF 280A SOFT
0
0 50 100 150 200 250 300 350 400 450
DC AMPS

xx18 Stick VA Curve

100

90

80
575V Primary
70

60
DC VOLTS

50

40 208V Primary

30

20

10 30A 30A STIFF 280A

280A SOFT
SOFT STIFF
0
0 50 100 150 200 250 300 350 400
DC AMPS

Ref. 221 588-A

OM-217 655 Page 11

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 3-4. TIG (GTAW) Volt-Ampere Curve CST 280 Model
Volt-ampere curves show minimum
TIG VA Curve and maximum voltage and
amperage output capabilities of
80 welding power source. Curves of
other settings fall between curves
70 shown.

60

50
DC VOLTS

40

30

20

10

0
0 50 100 150 200 250 300
DC AMPS

Ref. 221 588-A

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 3-5. Stick (SMAW) Volt-Ampere Curves CST 280 VRD Model
Volt-ampere curves show minimum
and maximum voltage and
xx10 Stick VA Curves amperage output capabilities of
welding power source. Curves of
other settings fall between curves
90 shown.

80

70

60
DC VOLTS

50

40

30
280A STIFF
20

10
30A SOFT 30A STIFF 280A SOFT
0
0 50 100 150 200 250 300 350 400
DC AMPS

xx18 Stick VA Curve

90

80

70

60
DC VOLTS

50

40

30

20

10
30A 30A STIFF 280A 280A
SOFT SOFT STIFF
0
0 50 100 150 200 250 300 350 400
DC AMPS

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 3-6. TIG (GTAW) Volt-Ampere Curve CST 280 VRD Model
Volt-ampere curves show minimum
TIG VA Curve and maximum voltage and
amperage output capabilities of
35
welding power source. Curves of
other settings fall between curves
shown.
30

25

20
DC VOLTS

15

10

0
0 50 100 150 200 250 300
DC AMPS

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 3-7. Selecting A Location
1 Line Disconnect Device
Locate unit near correct input
power supply.
Dimensions And Weight  Special installation may be
40 lb (18.2 kg) - with power cord required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
18 in
Section 20.
(457 mm)

13-1/2 in
(343 mm)

7-1/2 in
(191 mm)

Location And Airflow

18 in
(460 mm)

18 in
(460 mm)

803 942-A

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 3-8. Weld Output Terminals And Selecting Cable Sizes*

 ARC WELDING can cause Electromagnetic Interference.

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

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
 Turn off power before 10
60 100%
connecting to weld out- Welding 60%
Duty 10 100% Duty Cycle
put terminals. Amperes*** Duty
Cycle
 Do not use worn, dam- Cycle
aged, undersized, or
poorly spliced cables.

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)
+
Output Receptacles 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***Select weld cable size for pulsing application at peak amperage value. S-0007-F803 080

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 3-9. TIG Lift-Arct DCEN (Direct Current Electrode Negative) Connections
1 Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4 2 Negative () Weld Output
5
Terminal
6 Connect TIG torch to negative weld
output terminal.

3 3 Gas Cylinder
4 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5 Regulator/Flowmeter
6 Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas hose to
regulator/flowmeter.
1 7 Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.

2
7

Tools Needed:

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

803 943-A

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 3-10. Stick DCEP (Direct Current Electrode Positive) Connections
1 Negative () Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2 Positive (+) Weld Output
Terminal
Connect electrode holder to
positive weld output terminal.

803 944-A

3-11. Electrical Service Guide

 CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding
power source requires a CONTINUOUS supply of 50/60 Hz power at +10% of rated input voltage. Do
not use a generator with automatic idle device (that idles engine when no load is sensed) to supply
generator input power to this welding power source.

NOTE Actual input voltage cannot exceed 10% of indicated required input voltage. If
actual input voltage is outside of this range, inadvertent shutdown may occur.

50/60 Hz Single-
50/60 Hz Three-Phase,
Phase, 50% Duty
35% Duty Cycle
Cycle

Input Voltage 208 220 230 208 220 230 400 460 575

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

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay 2 50 50 50 45 45 45 25 20 15

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

Min Input Conductor Size In AWG4 8 8 8 10 10 10 14 14 14

117 129 141 101 113 123 149 196 306

Max Recommended Input Conductor Length In Feet (Meters)
(36) (39) (43) (31) (34) (38) (45) (60) (93)

Min Grounding Conductor Size In AWG4 8 8 8 10 10 10 14 14 14

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 Time-Delay fuses are UL class RK5 .
3 Normal Operating (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.
 Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
OM-217 655 Page 18

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 3-12. Selecting 208 - 230 Volts AC Single/Three Phase Input Voltage
 Turn Off welding power
source, and disconnect
input power before
proceeding.
208-230/400-460 Volts Model Check input voltage available at
1 site.
1 Switch Cover
2 Voltage Selection Switch
The input voltage that the power
source is linked for is labeled next to
the switch.
208230 400460
VAC VAC Check voltage selected on unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
2
 Do not switch under load.
To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position

at 905 straight up.
Be sure that switch is turned
completely to its detent position.

220-230/460-575 Volts Model

1

220230 460575
VAC VAC

Tools Needed:

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

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 3-13. Selecting 400 - 575 Volts AC Three Phase Input Voltage
 Turn Off welding power
source, and disconnect
input power before
proceeding.
208-230/400-460 Volts Model
1 Check input voltage available at
site.
1 Switch Cover
2 Voltage Selection Switch
The input voltage that the power
source is linked for is labeled next to
208230 400460 the switch.
VAC VAC
Check voltage selected on unit.
Changing selection is only
necessary if selected value does
2 not match available input voltage.
 Do not switch under load.
To change selection switch
position, open switch cover and
turn switch to the required voltage
range.

 The switch has an off position

at 905 straight up.
Be sure that switch is turned
completely to its detent position.

220-230/460-575 Volts Model

1

220230 460575
VAC VAC

Tools Needed:

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

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 3-14. Connecting 1-Phase Input Power
 Installation must meet all National
and Local Codes have only quali-
fied persons make this installation.
 Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
 Always connect green or green/
1 yellow conductor to supply
grounding terminal first, and never
to a line terminal.
See rating label on unit and check input
8 =GND/PE Earth Ground voltage available at site.
1 Black And White Input Conductor
(L1 And L2)
10
2 Red Input Conductor
3 Green Or Green/Yellow Grounding
Conductor
7 4 Insulation Sleeving
5 Electrical Tape
9 Insulate and isolate red conductor as
shown.
6 Input Power Cord.
L1 7 Disconnect Device (switch shown in
1
L2 the OFF position)
3 8 Disconnect Device Grounding
Terminal
1 9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
6 conductor to disconnect device grounding
terminal first.
2 Connect input conductors L1 and L2 to
disconnect device line terminals.
3
10 Over-Current Protection
Select type and size of over-current
6 protection using Section 3-11 (fused dis-
connect switch shown).
4
5 Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

803 766-A / 803 942-A

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 3-15. Connecting 3-Phase Input Power
 Installation must meet all National
and Local Codes have only quali-
fied persons make this installation.

3  Disconnect and lockout/tagout in-

put power before connecting input
conductors from unit.
 Always connect green or green/
= GND/PE Earth Ground yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4 See rating label on unit and check input
voltage available at site.
1 Input Power Cord.
2 Disconnect Device (switch shown in
7 the OFF position)
3 Green Or Green/Yellow Grounding
Conductor
4 Disconnect Device Grounding
Terminal
5 Input Conductors (L1, L2 And L3)
2
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
L1 7 Over-Current Protection

3 Select type and size of over-current

L2 5
protection using Section 3-11 (fused dis-
connect switch shown).
6 L3
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

803 766-A / 803 942-A

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 SECTION 4 OPERATION
4-1. Controls
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1 Power Switch
Use switch to turn unit and indicator light
On/Off.
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2 5
2 Output Indicator Light
When unit is first energized this indicator
light flashes several times and then
illuminates continuously. When unit is shut
down, the indicator light flashes several
times and the cooling fan will run briefly,
then both will turn off completely.
3 Process Control
See Section 4-2.
3 4
4 Amperage Control
See Section 4-5.
5 High Temperature Shutdown Light
When unit is first energized this indicator
light illuminates for approximately 1 second
to provide visual confirmation that the light
is functioning properly (see Section 3-2).
6 Remote 14 Receptacle
Ref. 217 192-A / 803 942-A
OM-217 655 Page 23
 4-2. Process Select Control
1 Process Select Control
Rotate knob to select desired
process.
Lift-Arc TIG - Normal
1 open-circuit voltage is not present
between the electrode and
workpiece. A solid-state contactor
does not energize until after the
electrode touches the workpiece,
preventing overheating, sticking, or
contaminating the electrode (see
Section 4-4). Make connections
according to Section 3-9.
Stick E XX18 Soft - This setting
provides a lower dig/arc force
setting for smooth weld perfor-
mance. A stable weld puddle with
little arc snap gives excellent weld
bead appearance with minimal
spatter. Make connections
according to Section 3-10.
Stick E XX18 Stiff - This setting
provides a higher dig/arc force that
gives a slightly more fluid weld
puddle, more arc snap, and
reduces the potential for electrode
sticking at shorter arc lengths.
Make connections according to
Section 3-10.
Stick E XX10 Soft - This setting
provides lower dig/arc force for
open root vertical up joints or joints
that do not require additional
current for fit up inconsistencies.
RECOMMENDED PROCESS Make connections according to
SELECTIONS VS ELECTRODE TYPE Section 3-10.
Stick E XX10 Stiff - This setting
ELECTRODE SUGGESTED PROCESS provides a higher dig/arc force for
TYPE SETTING open root vertical down joints
where additional current is needed
EXXX1 EXX10 to compensate for tight joint fit up
EXXX2 EXX10 without the need to increase overall
welding current. Make connections
according to Section 3-10.
EXXX3 EXX18
EXXX4 EXX18
EXXX5 EXX18
EXXX6 EXX18
EXXX7 EXX18
EXXX8 EXX18
STAINLESS EXX18

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 4-3. Stick Start Procedure Scratch Start Technique
With Stick selected, start arc as
follows:
1 Electrode
2 Workpiece
3 Arc
1 Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If
electrode sticks to workpiece, use a
quick twist to free it.
2 VRD Model Only: Normal
open-circuit voltage is not present
before electrode touches workpiece;
3 only a low sensing voltage is present
between electrode and workpiece.
This allows electrode to touch
workpiece without overheating,
sticking, or getting contaminated.

4-4. Lift-Arc Start Procedure

Lift-Arc Start
With Lift-Arc selected, start arc
as follows:
1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten
electrode to workpiece at weld start
point. Hold electrode to
Lift-Arc Start Method workpiece for 1-2 seconds, and
1 2 slowly lift electrode. Arc is formed
when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
12 electrode and workpiece. The
Touch Seconds solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece
without overheating, sticking, or
getting contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to
replace the scratch method.

Do NOT Strike Like A Match!

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 4-5. Amperage Control
1 AMP ADJUST (Amperage
Control)
1
Rotate knob clockwise to increase
amperage (5-280 amps).

4-6. Remote 14 Receptacle Information

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

Socket* Socket Information

A J
K I
B
C L N H A 15 volts dc (not functional).
D M G 15 VOLTS DC
E F B Contact closure to A completes 15 volts dc
contactor control circuit (not functional).

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

REMOTE D Remote control circuit common.

OUTPUT
CONTROL
E 0 to +10 volts dc input command signal from
remote control.

K Chassis common.
803 942-A GND

*The remaining sockets are not used.

4-7. Fan-On-Demand
This unit is equipped with Fan-On-Demand. The fan operates only when necessary to cool internal components. At
power down, the fan will operate for a short period of time while the output indicator light is flashing.

4-8. Rack Mounting

This unit is capable of being rack mounted see rack Owners Manual, OM-221 611.

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 SECTION 5 MAINTENANCE AND TROUBLESHOOTING

5-1. Routine Maintenance

 Disconnect power before maintaining.

 Maintain more often during severe conditions.

3 Months

Replace Clean and tighten Replace Damaged

unreadable weld terminals. Gas Hose
labels.

3 Months

Repair Or Replace
Cracked Cables
And Cords

6 Months
 Do not remove case when
blowing out inside of unit
(see Section 5-2) .
Blow out inside. During
heavy service clean
monthly.

5-2. Blowing Out Inside Of Unit

 Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.

803 942-A

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 5-3. Troubleshooting
1 Output LED (Blue)
2 High Temperature LED
(Yellow)

803 942-A

Repeated LED Flashes Indicate

Status
Red (LED3
Blue Yellow Trouble Possible Causes Remedy
on PC3)
Place line disconnect switch in
Line Disconnect open. on position (see Section 3-14 or
3-15).
Check and replace line fuses, if
No weld output; necessary, or reset circuit
None None None unit completely Blown fuses.
breaker (see Section 3-14 or
inoperative. 3-15).
Check for proper input connec-
Improper input connections.
tions (see Section 3-12 or 3-13).
Fuse F1 on PC2 blown. Check and replace F1.
Line voltage too high or
Line voltage must be 10%.
too low.

Flashes Con- Check line voltage and link ac-

0 7 No weld output. Not ready. Unit is linked incorrectly.
tinuously cordingly.
Check DC buss caps and PC2,
Buss voltage imbalance.
and replace if necessary.
Check CT1 and wiring for an
No primary lfb.
open condition.
Check for shorts or opens in
Failed output diode(s).
wiring.

6 0 1 No weld output. Current latch. Replace boost inductor if neces-

4 0
Failed boost inductor.
sary.
Failed LEM. Replace LEM if necessary.
Open connection be- Inspect all wiring and connec-
tween LEM and PC1. tions.
Check for a shorted relay or wir-
Shorted boost relay.
ing.
Boost relay does not
deenergize after termina- Check PC1.
8 No weld output. Voltage latch. tion of weld.
Voltage in excess of
100V from another Check for external voltage
source applied across sources.
output studs.

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 Repeated LED Flashes Indicate
Status
Red (LED3
Blue Yellow Trouble Possible Causes Remedy
on PC3)
Vfb leads not connected Check Vfb leads for proper wir-
or reversed. ing and connection.
Short circuit across out-
5 0 11 No weld output. Voltage loss. Check for shorts.
put studs.
Check PC2 and replace if nec-
Failed IGBT on PC2.
essary.

Output fold- Single phase rating ex- Reduce output to 200 amperes
Reduced weld back due to ceeded. or less.
2 0 6
output. excessive in- High output VA coupled Check line voltage and weld
put current. with a low 230V line. settings.
Remove trigger, wait approxi-
3 0 10 Remote trigger has been left on.
mately 5 seconds, and restart.
Primary (IGBT) thermis- Allow unit to cool down.
3 No weld output.
On Unit over
over- tor over temperature. Retorque PM1, PM2, and PM3
0
continuously heated. Secondary thermistor mounting hardware to 25 in lbs
5 (2.8 Nm).
over temperature.
Shorted primary (IGBT) Check IGBT thermistors for
0
thermistor. shorts.
Open primary (IGBT) Check IGBT thermistors and
2
thermistor. associated wiring for opens.
Flashes Thermistor Check thermistor on output
0 No weld output. Open secondary thermis-
continuously 4 failure. heatsink and associated wiring
tor.
for opens.
Check thermistor on ouput heat-
Shorted secondary
9 sink and associated wiring for
thermistor.
shorts.
Check for and remove anything
Blocked fan.
Fan not operat
operat- blocking fan movement.
N/A N/A N/A
ing. Have factory authorized service
Fan failure.
agent check fan motor.
Use proper size and type of
Weld cables too small or defective.
Erratic or im
im- weld cables (see Section 3-8).
N/A N/A N/A proper weld Clean and tighten all weld cable
output. Dirty or loose connections. connections (see Section 3-9 or
3-10).
Use proper size tungsten (see
Improper tungsten.
Section 7-1).
Use properly prepared tungsten
N/A N/A N/A Wandering arc. Worn or defective tungsten.
(see Section 7-3).
Reduce gas flow rate (see Sec-
Gas flow too high.
tion 3-9).
Gas is blown away from weld zone. Shield weld zone from drafts.
Tungsten elec- Allow adequate postflow time to
trode oxidizing Inadequate postflow time. shield tungsten while it is cool-
and not remain- ing after welding stops.
N/A N/A N/A ing bright after
conclusion of Check and tighten all gas fit-
Loose or leaking gas fittings.
weld. tings (see Section 3-9).
Water in torch. Refer to torch manual.

OM-217 655 Page 29

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 SECTION 6 ELECTRICAL DIAGRAMS

Figure 6-1. Circuit Diagram

OM-217 655 Page 30

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 217 589-B

OM-217 655 Page 31

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 SECTION 7 SELECTING AND PREPARING TUNGSTEN
ELECTRODE
gtaw 7/97

NOTE For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.

7-1. Selecting Tungsten Electrode

Amperage Range - Gas Type - Polarity

Electrode Diameter DC Argon Electrode DC Argon Electrode AC Argon Using AC Argon Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
2% Thorium Alloyed
Tungsten (Red Band)
.010 Up to 25 * Up to 20 Up to 15
.020 15-40 * 15-35 5-20
.040 25-85 * 20-80 20-60
1/16 50-160 10-20 50-150 60-120
3/32 135-235 15-30 130-250 100-180
1/8 250-400 25-40 225-360 160-250
5/32 400-500 40-55 300-450 200-320
3/16 500-750 55-80 400-500 290-390
1/4 750-1000 80-125 600-800 340-525

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

The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.

7-2. Safety Information About Tungsten

 Grinding the tungsten elec-
trode produces dust and fly-
ing sparks which can cause
injury and start fires. Use lo-
1 cal exhaust (forced ventila-
tion) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-lev-
2 el radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1 Tungsten Electrode With
Balled End
2 Pointed Tungsten Electrode

Ref. S-0161

OM-217 655 Page 32

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 7-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1 Tungsten Electrode
1 2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.

2-1/2 Times
Electrode Diameter

1 Stable Arc
2 Flat
1
Diameter of this flat determines
amperage capacity.
2
3 Grinding Wheel
3 Grinding wheel should be dedi-
cated to grinding tungsten only.
4 Straight Ground

4
Ideal Tungsten Preparation Stable Arc

1 Arc Wander
2 Point
1 3 Grinding Wheel
Grinding wheel should be dedi-
2 cated to grinding tungsten only.
4 Radial Ground

Wrong Tungsten Preparation Wandering Arc

Ref. S-0161 / Ref. S-0162

OM-217 655 Page 33

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 SECTION 8 PARTS LIST

 Hardware is common and

not available unless listed.

10 8

24
18
17

15 15

6 11

23

22
13
13
12 20

30 7 26

21
16
9
14
3

19 2

16

25

803 947-B

Figure 8-1. Main Assembly

OM-217 655 Page 34

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 Quantity
Model
Item Part
No. No. Description 907 251 907 244

Figure 8-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . 221585 .. PANEL,FRONT W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

. . . 2 . . . . . . . . . . . . . . 221586 .. PANEL,REAR W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 3 . . . . . . . . . . . . . . 212809 .. MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 206037 .. MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 206090 .. HEAT SINK ASSEMBLY,OUTPUT DIODE . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 5 . . . . . . . . . . . . . . 206039 .. BASE ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 6 . . . . . . . . . . . . . . 206093 .. BRACKET,MTG CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 7 . . . . . . . . . . . . . . 206038 .. HEAT SINK ASSEMBLY,INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 8 . . . . . . . . . . . . . +217216 .. WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . 203990 .. LABEL,WARNING GENERAL PRECAUTIONARY STATIC . . . . 1 . . . . 1
. . . 9 . . . . . . . . . . . . . +207437 .. CABLE,POWER 6 FT 10GA 4C BLK/RED/WHT/GRNYEL . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . 182826 .. LABEL,WARNING ELECTRIC SHOCK POWER CORD . . . . . . . 1 . . . . 1
. . . 10 . . . . . . . . . . . . . . 206108 .. HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 11 . . . . . . . . . . . . . . 206289 .. LINK,CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 1
. . . 12 . . PLG3 . . . . . 206247 .. PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 13 . . PLG4 . . . . . 206254 .. PLUGS,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 14 . . . . . . . . . . . . . . 196231 .. XFMR,CURRENT SENSING 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 15 . . . . . . . . . . . . . . 206270 .. INSULATOR,SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 16 . . PLG5 . . . . . 206276 .. CABLE,LEM W/PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 17 . . C1,C2 . . . . +203912 .. CAPACITOR,ELCTLT 2400 UF 500 VDC CAN 2.5 DIA . . . . . . . . 2 . . . . 2
. . . . . . . . . . . . . . . . . . . . 126026 .. LABEL,WARNING ELECTRIC SHOCK CAN KILL SIGNIFICANT 2 . . . . 2
. . . 18 . . . . . . . . . . . . . . 205908 .. CLAMP,CAPACITOR 2.500 DIA HORIZONTAL MTG NYLON . . 1 . . . . 1
. . . 19 . . . . . . . . . . . . . . 189777 .. RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 20 . . . PC2 . . . . . . 222447 .. KIT,CIRCUIT CARD ASSY INTERCONNECT . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 21 . . . PC1 . . . . . . 221472 .. CIRCUIT CARD ASSY,POWER CONTROL . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 22 . . . . . . . . . . . . . . 217587 .. FUSE,CRTG 2. AMP 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 23 . . . . . . . . . . . . . . 176879 .. SCREW,M 5 .8X 12 HEX HDPHL . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 6
. . . 24 . . . . . . . . . . . . . . 207113 .. WASHER,CONE .205IDX0.394ODX.015T STL . . . . . . . . . . . . . . . 2 . . . . 2
. . . 25 . . . . . . . . . . . . . . 200550 .. SCREW,M101.5X 20 HEX HDPLN 8.8 PLD SEMS . . . . . . . . . 2 . . . . 2
. . . 26 . . . . . . . . . . . . . . 217249 .. SWITCH ASSY,RELINKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-217 655 Page 35

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  Hardware is common and 8
not available unless listed.
19 20

4 24
7
2
18

14
23

9
13
12
25
6 22 15
5 3
7

17
11
21 16

10 803 158-A

Figure 8-2. Panel, Front w/Components

Quantity
Model
Item Dia. Part 907251 907244 907251012
No. Mkgs. No. Description

Figure 8-2. Panel, Front w/Components

... 1 .............. 194242 .. PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1

... 2 .............. 205759 .. PANEL,FRONT UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 3 .............. 195647 .. PANEL,FRONT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 4 . . . . S1 . . . . . . 207165 .. SWITCH,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 5 .............. 174991 .. KNOB,POINTER 1.250 DIA X .250 ID
W/SPRING CLIP.21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
. . . 6 . . . . . . . . . . . . . . 174992 . . KNOB,POINTER .840 DIA X .250 ID
W/SPRING CLIP.21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 7 . . RC14 . . . . . 207144 .. RECEPTACLE W/LEADS&PLUG,(14 PIN) . . . . . . . . . . . . 1 . . . . 1 .... 1
... 8 .............. 193115 .. STANDOFF SUPPORT,PC CARD .156 DIA/.375 LG . . 3 . . . . 3 .... 3
... 9 .............. 178548 .. TERMINAL,CONNECTOR FRICTION . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 10 .............. 209473 .. RECEPTACLE,TWIST LOCK TWECO(FEMALE) . . . . . . 2
... 10 .............. 202553 .. RECEPTACLE,TWIST LOCK DINSE(FEMALE) . . . . . . . . . . . . . . 2 .... 2
... 11 .............. 185712 .. INSULATOR,BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 12 .............. 185713 .. INSULATOR,BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 13 .............. 185714 .. WASHER,TOOTH 22MMID X 31.5MMOD
1.3101MMT INTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 14 .............. 185717 .. NUT,M201.5 1.06HEX .19H BRS LOCKING . . . . . . . . . 2 . . . . 2 .... 2
... 15 .............. 185718 .. ORING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 16 .............. 186228 .. ORING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 .... 2
... 17 .............. 207253 .. BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
... 18 .............. 217192 .. NAMEPLATE,MILLER CST 280 . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 .... 1
OM-217 655 Page 36

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 Quantity
Model
Item Dia. Part 907251 907244 907251012
No. Mkgs. No. Description

Figure 8-2. Panel, Front w/Components (Continued)

... 19 . . . PC4 . . . . . . 205764 .. CIRCUIT CARD ASSY,OPERATOR INTERFACE . . . . . . 1 . . . . 1 . . . . 1

... 20 . . . PC3 . . . . . . 221467 .. CIRCUIT CARD ASSY,PROCESS CONTROL . . . . . . . . 1 . . . . 1
... 20 . . . PC3 . . . . . . 221619 .. CIRCUIT CARD ASSY,PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . 1
... 21 .............. 170391 .. CONNECTOR, CIRC MS PROTECTIVE CAP . . . . . . . . . 1 . . . . 1 . . . . 1
... 22 .............. 178355 .. NUT, 37532 .54HEX .25H NYL FLANGE .62D . . . . . . . 2 . . . . 2 . . . . 2
... 23 .............. 209554 .. SCREW, KA35X 8 PAN HDPHL . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
... 24 .............. 097132 .. STANDOFF,NO 632 X .375 LG .250 HEX BRS M&F . 1 . . . . 1 . . . . 1
... 25 .............. 230485 .. KNOB,SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
 Hardware is common and
not available unless listed.

2
3
803 948-A

Figure 8-3. Panel, Rear w/Components

Item Part
No. No. Description Quantity

Figure 8-3. Panel, Rear w/Components

... 1 . . . . . . . . . . 194242 .. PANEL,FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . 206053 .. PANEL,REAR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . 210128 .. BRACKET,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . 145217 .. SCREW,K40X 12 PAN HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . 207253 .. BLANK,HEX HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . 201155 .. BUSHING,STRAIN RELIEF .450/.709 ID X1.068 MTG HOLE . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-217 655 Page 37

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  Hardware is common and 10
not available unless listed.

8
11

13

8
1
12

5
2
4 804 206-A

Figure 8-4. Magnetics Subassembly

Quantity
Item Diagram Part Model
No. Marking No. Description 907 251 907 244

Figure 8-4. Magnetics Subassembly

... 1 .............. 206063 .. PANEL,PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . T1 . . . . . . 212812 .. XFMR,HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . . T1 . . . . . . 206065 .. XFMR,HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . FM . . . . . . 196887 .. FAN,MUFFIN 24VDC 3000 RPM 130 CFM 4.125 MTG HOLES 1 . . . . 1
... 4 . . . . Z1 . . . . . . 206064 .. INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 5 . . . CR1 . . . . . . 206258 .. RELAY,ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . 1 . . . . 1
... 6 . . . . R3 . . . . . . 206281 .. RESISTOR,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 7 . . . . C3 . . . . . . 196143 .. CAPACITOR,POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . 1 . . . . 1
... 8 .............. 057357 .. BUSHING,SNAPIN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . 3 . . . . 3
... 9 . . . . L3 . . . . . . 225189 .. COIL,INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 10 .............. 198634 .. BRACKET,FRONT HEATSINK MTG . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 11 .............. 083147 .. GROMMET,SCR NO 8/10 PANEL HOLE .312 SQ .500 HIGH . . 1 . . . . 1
... 12 .............. 136343 .. SCREW,K50X 20 PAN HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
... 13 .............. 170647 .. BUSHING,SNAPIN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . 1 . . . . 1

To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-217 655 Page 38

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  Hardware is common and
not available unless listed.

3 803 949-B

Figure 8-5. Relinking Switch And Door Assembly

Quantity
Model
Item Dia. Part
No. Mkgs. No. Description 907 251 907 244

Figure 8-5. Relinking Switch And Door Assembly

. . . 1 . . . . . . . . . . . . . +217252 .. DOOR ASSY,RELINKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

. . . . . . . . . . . . . . . . . . . . 221460 .. LABEL,220230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221461 .. LABEL,460575 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221458 .. LABEL,208230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221459 .. LABEL,400460 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 221462 .. LABEL,,CAUTION OPERATING LINK SWITCH ETC . . . . . . . . . 1 . . . . 1
. . . 2 . . . . . . . . . . . . . . 217647 .. SWITCH,ROTARY 3 POSN 4P 32A 600V 180 DEG (SPL) . . . . . 1 . . . . 1
. . . 3 . . . . . . . . . . . . . . 209554 .. SCREW,KA35X 8 PAN HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 4 . . . . . . . . . . . . . . 221573 .. NUT,SPEED SNAPIN 1/4 TURN . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 5 . . . . . . . . . . . . . . 221575 .. RETAINER,NYLON PUSHON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 6 . . . . . . . . . . . . . . 221574 .. SCREW,1/4 TURN OVAL HDPHL . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2

+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 Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-217 655 Page 39

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  Hardware is common and 10
not available unless listed.
11
12
12

7
6
2

9
3
8

803 159-D

Figure 8-6. Heat Sink Assembly, Output Diode

Item Diagram Part

No. marking No. Description Quantity

Figure 8-6. Heat Sink Assembly, Output Diode

... 1 . . . . . . . . . . 205916 .. HEAT SINK,DIODE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . D1,D2 . 223422 .. KIT,DIODE ULTRAFAST RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . SR1 . . 201530 .. KIT,DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . HD1 . . 191941 .. TRANSDUCER,CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . R2,C6 . 196510 .. RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . R1,C5 . 207384 .. RESISTOR/CAPACITOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . RT1 . . 209223 .. THERMISTOR,NTC 30K OHM @ 25 DEG C 18IN LEAD . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . 049611 .. TUBING,COP .540 OD X .123 WALL X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . 207932 .. INSULATOR,HEATSINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . 108942 .. SCREW,25020X1.25 HEXWHD.61D GR5 PLD . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . 602 062 .. SCREW,00440X .37 PAN HDPHL STL PLD CONE SEMS . . . . . . . . . . . . . 5
... 12 . . . . . . . . . . 207451 .. SCREW,00832X .50 PAN HDPHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . . 7

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

OM-217 655 Page 40

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  Hardware is common and
not available unless listed.

1
6
7
8

2
5

803 160

Figure 8-7. Base Assembly

Item Diagram Part

No. marking No. Description Quantity

Figure 8-7. Base Assembly

... 1 .......... 206089 .. BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .......... 019663 .. MOUNT,NPRN 15/16ODX3/8REC 3/16X3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 3 . . C7,C8 . 186543 .. CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 .......... 133528 .. RIVET,AL .125 DIA X .188.250 GRIP BLK BLIND DOME . . . . . . . . . . . . . . . 4
... 5 .......... 195666 .. SCREW,01032X .62 HEXWHD.40D STL PLD SLFFMG TAPRW . . . . . . . . 2
... 6 .......... 601862 .. NUT, 01032 .38HEX .13H STL PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 7 .......... 602203 .. WASHER,LOCK .193IDX0.334ODX.047T STL PLD SPLIT #10 . . . . . . . . . . . 2
... 8 .......... 602238 .. WASHER,FLAT .203IDX0.500ODX.048T STL PLD ANSI#10 . . . . . . . . . . . . . 2

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

OM-217 655 Page 41

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  Hardware is common and
not available unless listed.

803 162-B

Figure 8-8. Heat Sink Assembly, Input

Item Diagram Part

No. marking No. Description Quantity

Figure 8-8. Heat Sink Assembly, Input

. . . 1 . . . . . . . . . . 205915 . . HEAT SINK,IGBT/INPUT RECTIFIER MODULE . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . 206091 . . BRACKET,HEATSINK REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . TE1 . . 206328 . . BLOCK,TERM 70 AMP 3 POLE SCREW TERM 414 WIRE . . . . . . . . . . . . . 1

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

OM-217 655 Page 42

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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.
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Effective January 1, 2007
(Equipment with a serial number preface of LH or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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
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/TIG Torches and Subarc (SAW) Guns
* 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
Millers 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 manufacturers 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 Millers 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
customers risk and expense. Millers 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 200701
 Owners 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
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International HeadquartersUSA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller 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 manufacturers
Transportation Department.

PRINTED IN USA 2007 Miller Electric Mfg. Co. 200701

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