OM-202 137V

201201

Processes
Multiprocess Welding

Description

Arc Welding Power Source

UWI 400
(380/440 Volt Model) CE

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utiliss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Manufacturers Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. WEEE Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Lift-Arc Trigger Hold TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Voltmeter/Ammeter Help Displays (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
3
4
4
4
5
5
5
7
8
9
9
11
11
13
14
15
15
15
15
16
16
17
17
18
19
20
21
22
22
23
24
25
26
26
26
27
28
29
29
30
32

DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
UWI 400

Stock Number
670398

Council Directives:
2006/95/EC Low Voltage
2004/108/EC Electromagnetic Compatibility

Standards:
IEC 609741: 2005 Arc Welding Equipment Welding Power Sources
IEC 6097410: 2007 Arc Welding Equipment Electromagnetic Compatibility Requirements
EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0 Hz 300Hz) BS EN 50445:2008.

US Signatory:

October 25, 2010

_____________________________________

________________________________________

David A. Werba

Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

241526C

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

som 201110
7

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

1-1. Symbol Usage

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

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.

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.

D Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owners Manual and national, state, and local codes.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-202 137 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturers instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
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.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-202 137 Page 2

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

contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)

can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

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

FIRE OR EXPLOSION hazard.

BATTERY EXPLOSION can injure.

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

combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.

D Do not use welder to charge batteries or jump

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

MOVING PARTS can injure.

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94110) when manually lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.

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

guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.

READ INSTRUCTIONS.
D Read and follow all labels and the Owners
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owners
Manuals, industry standards, and national, state, and local
codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires keep flammables away.

STATIC (ESD) can damage PC boards.

D
D
D
D

D Put on grounded wrist strap BEFORE handling

boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.

ARC WELDING can cause interference.

MOVING PARTS can injure.

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

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.

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

navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

D
D
D

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
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.

OM-202 137 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passersby or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.

OM-202 137 Page 4

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

fre_som_201110
7

Pour carter les risques de blessure pour vousmme et pour autrui lire, appliquer et ranger en lieu sr ces consignes relatives
aux prcautions de scurit et au mode opratoire.

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si on
lvite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrs par les symboles
joints ou sont expliqus dans le texte.
Indique une situation dangereuse qui si on lvite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrs par les symboles joints ou
sont expliqus dans le texte.
NOTE Indique des dclarations pas en relation avec des blessures
personnelles.

. Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
affrant pour les actions ncessaires afin dviter le danger.

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 fonctionner, entretenir et rparer cet appareil.
Pendant le fonctionnement, maintenir distance toutes les
personnes, 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.
D Ne pas toucher aux pices lectriques sous tension.
D Porter des gants isolants et des vtements de protection secs et
sans trous.
D 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.
D Ne pas se servir de source lectrique courant lectrique dans les
zones humides, dans les endroits confins ou l o on risque de
tomber.
D Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande.
D Si lutilisation dune source lectrique courant lectrique savre
ncessaire, se servir de la fonction de tlcommande si lappareil
en est quip.
D 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, genoux 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,

D
D

D
D
D
D
D
D
D
D
D
D
D
D
D
D
D

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).
Installez, mettez la terre et utilisez correctement cet quipement
conformment son Manuel dUtilisation et aux rglementations
nationales, gouvernementales 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.
Les cbles doivent tre exempts dhumidit, dhuile et de graisse;
protgezles contre les tincelles et les pices mtalliques
chaudes.
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-lechamp 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 mtalmtal 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. Dbrancher le
cble pour le procd non utilis.
OM-202 137 Page 5

Il reste une TENSION DC NON NGLIGEABLE dans

les sources de soudage onduleur UNE FOIS
lalimentation coupe.
D Arrter les convertisseurs, dbrancher le courant lectrique et
dcharger les condensateurs dalimentation selon les instructions
indiques dans la partie Entretien avant de toucher les pices.

LES PICES CHAUDES peuvent

provoquer des brlures.
D Ne pas toucher mains nues les parties
chaudes.
D Prvoir une priode de refroidissement avant de
travailler lquipement.
D Ne pas toucher aux pices chaudes, utiliser les outils recommands et porter des gants de soudage et des vtements pais pour
viter les brlures.

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 peut provoquer des
incendies et des brlures. Le contact accidentel de llectrode avec
des objets mtalliques peut provoquer des tincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vrifier et sassurer que lendroit ne prsente pas de danger.
D Dplacer toutes les substances inflammables une distance de
10,7 m de larc de soudage. En cas dimpossibilit les recouvrir
soigneusement avec des protections homologus.
D Ne pas souder dans un endroit l o des tincelles peuvent tomber
sur des substances inflammables.

LES FUMES ET LES GAZ peuvent

tre dangereux.

D Se protger et dautres personnes de la projection dtincelles et

de mtal chaud.

Le soudage gnre des fumes et des gaz. Leur

inhalation peut tre dangereux pour votre sant.

D Des tincelles et des matriaux chauds du soudage peuvent

facilement passer dans dautres zones en traversant de petites
fissures et des ouvertures.

D Eloigner votre tte des fumes. Ne pas respirer les fumes.

D Surveiller tout dclenchement dincendie et tenir un extincteur

proximit.

D lintrieur, ventiler la zone et/ou utiliser une ventilation force au

niveau de larc pour lvacuation des fumes et des gaz de
soudage.

D Le soudage effectu sur un plafond, plancher, paroi ou sparation

peut dclencher un incendie de lautre ct.

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

approuv.
D 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.
D Travailler dans un espace ferm seulement sil est bien ventil ou
en portant un respirateur alimentation dair. Demander toujours
un surveillant dment form de se tenir proximit. Des fumes et
des gaz de soudage peuvent dplacer lair et abaisser le niveau
doxygne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne prsente aucun danger.
D Ne pas souder dans des endroits situs proximit doprations
de dgraissage, de nettoyage ou de pulvrisation. La chaleur et
les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des mtaux munis dun revtement, tels que lacier
galvanis, 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 toxiques en cas de soudage.

LES RAYONS DE LARC peuvent

provoquer des brlures dans les
yeux et sur la peau.
Le rayonnement de larc du procd de soudage
gnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brlures
dans les yeux et sur la peau. Des tincelles sont projetes pendant le
soudage.
D Porter un casque de soudage approuv muni de verres filtrants
appropri pour protger visage et yeux pour protger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 numr dans les normes de scurit).
D Porter des lunettes de scurit avec crans latraux mme sous
votre casque.
D 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.
D Porter des vtements confectionns avec des matires rsistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-202 137 Page 6

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

des rservoirs, tambours, ou conduites, moins quils naient t
prpars correctement conformment AWS F4.1 et AWS A6.0
(voir les Normes de Scurit).
D Ne soudez pas si lair ambiant est charg de particules, gaz, ou vapeurs inflammables (vapeur dessence, par exemple).
D 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.
D Ne pas utiliser le poste de soudage pour dgeler des conduites geles.
D En cas de non utilisation, enlever la baguette dlectrode du portelectrode ou couper le fil la pointe de contact.
D Porter des vtements de protection dpourvus dhuile tels que des
gants en cuir, une chemise en matriau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes.
D Une fois le travail achev, assurezvous quil ne reste aucune
trace dtincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupecircuits appropris.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achev, assurezvous quil ne reste aucune
trace dtincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupecircuits appropris.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux chaud et avoir de la surveillance et un
extincteur proximit.

DES PIECES DE METAL ou DES

SALETES peuvent provoquer des
blessures dans les yeux.
D 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.
D Porter des lunettes de scurit avec crans latraux ou un cran
facial.

LES ACCUMULATIONS DE GAZ

risquent de provoquer des blessures
ou mme la mort.
D Fermer lalimentation du gaz comprim en cas
de non utilisation.
D Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction
dair homologu.

Les CHAMPS LECTROMAGNTIQUES (CEM)

peuvent affecter les implants mdicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants mdicaux doivent rester
distance.
D Les porteurs dimplants mdicaux doivent consulter leur
mdecin et le fabricant du dispositif avant de sapprocher de la
zone o se droule du soudage larc, du soudage par points, du
gougeage, de la dcoupe plasma ou une opration de chauffage
par induction.

LE BRUIT peut endommager loue.

Le bruit des processus et des quipements peut
affecter loue.
D Porter des protections approuves pour les
oreilles si le niveau sonore est trop lev.

LES BOUTEILLES peuvent exploser

si elles sont endommages.
Les bouteilles de gaz comprim contiennent du gaz
sous haute pression. Si une bouteille est
endommage, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
procd de soudage, les manipuler avec
prcaution.
D Protger les bouteilles de gaz comprim dune chaleur excessive,
des chocs mcaniques, des dommages physiques, du laitier, des
flammes ouvertes, des tincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou
de se renverser.
D Tenir les bouteilles loignes des circuits de soudage ou autres
circuits lectriques.
D Ne jamais placer une torche de soudage sur une bouteille gaz.
D Une lectrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurise risque dexplosion.
D Utiliser seulement des bouteilles de gaz comprim, rgulateurs,
tuyaux et raccords convenables pour cette application spcifique;
les maintenir ainsi que les lments associs en bon tat.
D Dtourner votre visage du dtendeur-rgulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque
la bouteille est utilise ou quelle est relie pour usage ultrieur.
D Utiliser les quipements corrects, les bonnes procdures et suffisamment de personnes pour soulever et dplacer les bouteilles.
D 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 scurit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU
DEXPLOSION.
D Ne pas placer lappareil sur, au-dessus ou
proximit de surfaces inflammables.
D Ne pas installer lappareil proximit de produits inflammables.
D Ne pas surcharger linstallation lectrique sassurer que
lalimentation est correctement dimensionne et protge avant
de mettre lappareil en service.

LA CHUTE DE LQUIPEMENT peut

provoquer des blessures.
D Utiliser lanneau de levage uniquement pour
soulever lappareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un quipement de levage de capacit
suffisante pour lever lappareil.
D En utilisant des fourches de levage pour dplacer lunit, sassurer que les fourches sont suffisamment longues pour dpasser
du ct oppos de lappareil.
D Tenir lquipement (cbles et cordons) distance des vhicules
mobiles lors de toute opration en hauteur.
D Suivre les consignes du Manuel des applications pour lquation
de levage NIOSH rvise (Publication N94110) lors du levage
manuelle de pices ou quipements lourds.

LEMPLOI
EXCESSIF
peut
SURCHAUFFER LQUIPEMENT.
D Prvoir une priode de refroidissement ; respecter le cycle opratoire nominal.
D Rduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages dair du poste.

LES TINCELLES PROJETES

peuvent provoquer des blessures.
D Porter un cran facial pour protger le visage et
les yeux.
D Affter llectrode au tungstne uniquement la
meuleuse dote de protecteurs. Cette
manuvre est excuter dans un endroit sr
lorsque lon porte lquipement homologu de
protection du visage, des mains et du corps.
D Les tincelles risquent de causer un incendie loigner toute substance inflammable.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pices.
D Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des
cartes de circuits imprimes.
OM-202 137 Page 7

Les PICES MOBILES peuvent

causer des blessures.

LE
RAYONNEMENT
HAUTE
FRQUENCE
(H.F.)
risque
de
provoquer des interfrences.

D Ne pas sapprocher des organes mobiles.

D Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.

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

provoquer des interfrences avec les quipements de radionavigation et de communication, les services de scurit et les ordinateurs.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.
D Ne pas appuyer sur la gchette avant den
avoir reu linstruction.
D Ne pas diriger le pistolet vers soi, dautres
personnes ou toute pice mcanique en
engageant le fil de soudage.

LEXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser lappareil de soudage pour
charger des batteries ou faire dmarrer
des vhicules laide de cbles de dmarrage,
sauf si lappareil dispose dune fonctionnalit
de charge de batterie destine cet usage.

D Demander seulement des personnes qualifies familiarises

avec des quipements lectroniques de faire fonctionner linstallation.
D Lutilisateur est tenu de faire corriger rapidement par un lectricien
qualifi les interfrences rsultant de linstallation.
D Si le FCC signale des interfrences, arrter immdiatement lappareil.
D Effectuer rgulirement le contrle et lentretien de linstallation.
D 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.

Les PICES MOBILES peuvent

causer des blessures.
D Sabstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir ferms et verrouills les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est ncessaire pour des travaux dentretien et de
dpannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifi.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand lentretien est termin et avant de rebrancher
lalimentation lectrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les
tiquettes et le Mode demploi avant linstallation, lutilisation ou lentretien de lappareil.
Lire les informations de scurit au dbut du
manuel et dans chaque section.
D Nutiliser que les pices de rechange recommandes par le
constructeur.
D Effectuer lentretien en respectant les manuels dutilisation, les
normes industrielles et les codes nationaux, dtat et locaux.

LE SOUDAGE LARC risque de

provoquer des interfrences.

D
D
D
D
D

D Lnergie lectromagntique risque de

provoquer des interfrences pour lquipement
lectronique sensible tel que les ordinateurs et
lquipement command par ordinateur tel que
les 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 quipement 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 prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

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)

OM-202 137 Page 8

Ce produit contient des produits chimiques, notamment du

plomb, dont ltat de Californie reconnat quils provoquent
des cancers, des malformations congnitales ou dautres
problmes de procration. Se laver les mains aprs
utilisation.

2-5. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant lectrique qui traverse tout conducteur gnre des champs
lectromagntiques (CEM) certains endroits. Le courant de soudage
cre un CEM autour du circuit et du matriel de soudage. Les CEM
peuvent crer des interfrences avec certains implants mdicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs dimplants mdicaux doivent tre prises: Limiter par
exemple tout accs aux passants ou procder une valuation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procdures suivantes pour minimiser lexposition aux
CEM provenant du circuit de soudage:

4. Maintenir la tte et le torse aussi loin que possible du matriel du

circuit de soudage.

1. Rassembler les cbles en les torsadant ou en les attachant avec

du ruban adhsif ou avec une housse.
2. Ne pas se tenir au milieu des cbles de soudage. Disposer les
cbles dun ct et distance de loprateur.
3. Ne pas courber et ne pas entourer les cbles autour de votre
corps.

En ce qui concerne les implants mdicaux :

5. Connecter la pince sur la pice aussi prs que possible de la

soudure.
6. Ne pas travailler proximit dune source de soudage, ni
sasseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dvidoir.

Les porteurs dimplants doivent dabord consulter leur mdecin avant

de sapprocher des oprations de soudage larc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le mdecin approuve, il est recommand de suivre les
procdures prcdentes.

OM-202 137 Page 9

OM-202 137 Page 10

SECTION 3 DEFINITIONS
3-1. Manufacturers Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1

Electric shock from welding electrode

or wiring can kill.

2
2.1
2.2

1.1 Wear dry insulating gloves. Do not

touch electrode with bare hand. Do
not wear wet or damaged gloves.

2.3
3

1.2 Protect yourself from electric shock by

insulating yourself from work and
ground.

3.1
3.2

1.3 Disconnect input plug or power before

working on machine.

1.1

2.1

1.2

2.2

Breathing welding fumes can be

hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local exhaust
to remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion
or fire.
Keep flammables away from welding.
Do not weld near flammables.
Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.

1.3

2.3

3.3 Do not weld on drums or any closed

containers.
4

Arc rays can burn eyes and injure

skin.

4.1 Wear hat and safety glasses. Use ear

protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5

Become trained and read the

instructions before working on the
machine or welding.

Do not remove or paint over (cover)

the label.

4.1

5
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

3.1

3.2

3.3

179310-B

OM-202 137 Page 11

2
3
1

6
4

V
V

5
>60s

219335-C

2
1

5
3

4
212073-C

Warning! Watch Out! There

are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 60 seconds after
power is turned off before
working on unit, OR
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.

Warning! Watch Out! There

are possible hazards as
shown by the symbols.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.

4/96

1
1
2
3

= < 60

4
5

179309-C

OM-202 137 Page12

Warning! Watch Out! There

are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.

2
2
3

Warning! Watch Out! There

are possible hazards as
shown by the symbols.
Beware of fire. Use of
incorrect extension cord can
cause fire.
Always use extension cord
that has the size of
conductors and total length as
specified in the table.
Table showing correct
conductor sizes and total
length of cord.

202563-B

1/96

3-2. WEEE Label

Do not discard this product with
general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.

OM-202 137 Page 13

3-3. Symbols And Definitions

Panel

Alternating
Current (AC)

Output

Circuit Breaker

Remote

On

Off

Gas Tungsten Arc

Welding

Negative

Voltage Input

Direct Current
(DC)

Positive

Inductance

Protective Earth
(Ground)

Constant Current

Constant Voltage

Foot Control

Line Connection

Arc Force

Shielded Metal Arc

Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Three Phase Static

Frequency ConverterTransformerRectifier

U0

Rated No Load
Voltage (Average)

Hz

Hertz

U1
IP

Pulsed

I1max

Amperage

Rated Maximum
Supply Current

OM-202 137 Page14

I1eff

Primary Voltage

Degree Of
Protection

U2
I2

Conventional
Load Voltage
Rated Welding
Current

X
%

Voltage

Duty Cycle

Percent

Lift-Arc Trigger
Hold Operation
(GTAW)

Single Phase

Three Phase

Maximum Effective
Supply Current

Increase

Lift-Arc Operation
(GTAW)

SECTION 4 INSTALLATION
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!

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

This equipment is built in accordance with EN 609741 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owners Manuals for all components of the welding circuit for additional EMF exposure
information.

S
S

The EMF assessment on this equipment was conducted at 0.5 meter.

At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.

B. Information On Electromagnetic Compatibility (EMC)

!

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

This equipment does not comply with IEC 61000312. If it is connected to a public low voltage system, it is the responsibility of
the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment may be connected.
ce-emc 2 2011-09

4-2. Serial Number And Rating Label Location

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

4-3. Specifications
Rated
Welding
Output

Voltage
Range

300 A @
32 Volts DC,
60% Duty Cycle

10 35

Amperage
Range

5 400

Maximum
Open-Circuit
Voltage DC

IP
Rating

70

23

Amperes Input at Rated

Load Output 50/60 Hz
380 V

440 V

KVA

KW

21.0
(0.*)

19.0
(0.*)

12.4
(0.09*)

11.5
(0.04*)

*While idling

Notes

OM-202 137 Page 15

4-4. 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, a
Help message is displayed (see
Section 6-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle before welding.
NOTICE Exceeding duty cycle
can damage unit and void warranty.

60% Duty Cycle

6 Minutes Welding

4 Minutes Resting

Overheating

15
Minutes

OR
Reduce Duty Cycle
Ref. SA-178 651

4-5. Volt-Ampere Curves

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

C. CC Mode

D. CV Mode

ARC CONTROL

va_curve1 4/95 SA-178 652 / SA-178 653

OM-202 137 Page 16

4-6. Dimensions And Weight

Hole Layout Dimensions
A

A
E

11-3/4 in. (298 mm)

1-11/16 in. (42 mm)

15-3/4 in. (400 mm)

19-3/32 in. (485 mm)

8-11/16 in. (221 mm)

1-17/32 in. (39 mm)

1/4-20 UNC -2B thread

24 in.
(610 mm)

17 in.
(432 mm)

D
C

12-1/2 in.
(318 mm)

Weight
B
76 lb (34.6 kg)
804 801-A

4-7. Selecting a Location

Movement

Lifting Handles

Use handles to lift unit.

Do not move or operate unit

where it could tip.

Hand Cart

Use cart or similar device to move

unit.
3

Line Disconnect Device

Locate unit near correct input

power supply.

Special installation may be

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

Location
4

18 in.
(460 mm)

18 in.
(460 mm)

Ref. ST-151 556 / 801 192

OM-202 137 Page 17

4-8. Weld Output Terminals And Selecting Cable Sizes

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

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***

Weld Output
Terminals

Turn off power before connecting to

weld output terminals.

Do not use worn,

damaged,
undersized, or poorly
spliced cables.

100 ft (30 m) or Less

Welding
Amperes

Output Receptacles

* This

10 60%
Duty
Cycle

150 ft
(45 m)

60 100%
Duty
Cycle

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
400 ft
(105 m) (120 m)

10 100% Duty Cycle

AWG (mm2)

AWG
(mm2)

AWG (mm2)

100

4 (20)

4 (20)

4 (20)

3 (30)

2 (35)

1 (50)

1/0 (60)

1/0 (60)

150

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95)

200

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

4/0 (120)

250

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0
(2x70)

2x2/0
(2x70)

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0
(2x70)

2x3/0
(2x95)

2x3/0
(2x95)

350

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0
(2x70)

2x3/0
(2x95)

2x3/0
(2x95)

2x4/0
(2x120)

400

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0
(2x70)

2x3/0
(2x95)

2x4/0
(2x120)

2x4/0
(2x120)

500

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0
(2x70)

2x3/0
(2x95)

2x4/0
(2x120)

3x3/0
(3x95)

3x3/0
(3x95)

600

3/0 (95)

4/0 (120)

2x2/0
(2x70)

2x3/0
(2x95)

2x4/0
(2x120)

3x3/0
(3x95)

3x4/0
(3x120)

3x4/0
(3x120)

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

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-J 201107

OM-202 137 Page 18

4-9. Remote 14 Receptacle Information

Socket*

Socket Information

24 volts AC. Protected by supplementary protector CB2.

Contact closure to A completes 24 volts AC contactor control circuit.

115 volts AC. Protected by supplementary protector CB1.

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

Output to remote control; 0 to +10 volts DC, +10

volts DC in MIG mode.

Remote control circuit common.

0 to +10 volts DC input command signal from remote control.

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

Current feedback; +1 volt DC per 100 amperes.

CC/CV select

Circuit common for 24 and 115 volts AC circuits.

Chassis common.

24 VOLTS AC
A
B

J
I

C L N
D M
E

115 VOLTS AC

G
F

REMOTE
OUTPUT
CONTROL

A/V
ST-801 192

AMPERAGE
VOLTAGE

GND
*The remaining sockets are not used.

Notes

OM-202 137 Page 19

4-10. Electrical Service Guide

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

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

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Three Phase
Input Voltage (V)

380

440

Input Amperes (A) At Rated Output

19

16

20

20

30

25

14

14

120 (37)

161 (49)

14

14

Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses 2
Normal Operating Fuses

Min Input Conductor Size In AWG 4

Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG

Reference: 2011 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 Time-Delay fuses are UL class RK5 . See UL 248.
3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amps), and UL class H ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

Notes

OM-202 137 Page 20

4-11. Connecting 3-Phase Input Power

!

Installation must meet all National

and Local Codes have only qualified persons make this installation.

Disconnect and lockout/tagout input power before connecting input

conductors from unit.

Always connect green or green/

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

3
= GND/PE Earth Ground
4

See rating label on unit and check input

voltage available at site.

For Three-Phase Operation

1
2
2
3
4
5
6

L1
3

L2

Connect green or green/yellow grounding

conductor to disconnect device grounding
terminal first.

L3

Input Power Cord.

Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals

Connect input conductors L1, L2, and L3

to disconnect device line terminals.
7

Over-Current Protection

Select type and size of over-current

protection using Section 4-10 (fused disconnect switch shown).

Close and secure door on disconnect

device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

ST-144 221 / ST-801 192 / 803 766-A

OM-202 137 Page 21

SECTION 5 OPERATION
5-1. Front Panel Controls

202 133

Power On/Off Switch

. The

fan motor is thermostatically

controlled and only runs when cooling is
needed.

Voltmeter (see Section 5-2)

Ammeter (see Section 5-2)

Voltage/Amperage Adjustment Control

Mode Switch

The Mode switch setting determines both the

process and output On/Off control (see Section 5-3. Source of control (panel or remote)
for the amount of output is selected on the
Voltage/Amperage Control switch.
For Air Carbon Arc (CAC-A) cutting and
gouging, place switch in Stick position. For

OM-202 137 Page 22

best results, place Inductance/Dig control in

the maximum position.
6 Voltage/Amperage Control Switch
For front panel control, place switch in Panel
position.
For remote control, make connections to Remote 14 receptacle, and place switch in
Remote position. In most modes, remote
control is a percent of the Voltage/Amperage
Adjustment control setting (the value selected on Voltage/Amperage Adjustment
control is maximum available on remote). In
the MIG mode, remote control provides full
range of unit output regardless of V/A Adjust
control setting.
7 Inductance/Dig Control
Control adjusts Dig when a Stick (SMAW)
welding position is selected on mode switch.

When set lower, short-circuit amperage at

low arc voltage is the same as normal welding
amperage.
When set higher, short-circuit amperage is increased at low arc voltage to assist with arc
starts as well as reduce sticking while welding (see volt-ampere curves in Section 4-5).
Select setting best suited for application.
Control adjusts inductance when a MIG
(GMAW) position is selected on the mode
switch. Inductance determines the wetness
of the weld puddle. When set higher, wetness (puddle fluidity) increases.
When pulsed MIG, or one of the TIG (GTAW)
processes is selected, this control is not functional.

5-2. Meter Functions

. The meters display the actual weld output values for approximately three seconds after the arc is broken.

Mode

Meter Reading At Idle

V

Lift-Arc Trigger
Hold TIG (GTAW)

85
Blank

Preset Amps

Blank

Preset Amps

85

TIG (GTAW)

MIG (GMAW)

Pulsed MIG
(GMAW-P)

24.5
Preset Volts

Blank

PPP

PPP

Pulse Display

Pulse Display

Blank

Preset Amps

Remote
Control SMAW

Panel Control
SMAW

85

80.0
Actual Volts (OCV)

85
Preset Amps

OM-202 137 Page 23

5-3. Mode Switch Settings

. The SMAW modes provide the Adaptive Hot Start feature, which automatically increases the output amperage at the start of a weld should the
start require it. This eliminates electrode sticking at arc start.

Mode

Output Control

Lift-Arc Trigger
Hold TIG (GTAW)

Select:

or

Amp

Requires:

TIG (GTAW) With

HF Unit,
Pulsing Device,
Or Remote Control

Select:

Control

or

Requires:

Select:

Amp

Control

or

Volt

MIG (GMAW)
Requires:

Pulsed MIG
(GMAW-P)
(Requires an
external
pulsing device.)

Select:

Feeder

Volt

Requires:

Select:

Feeder or Control

or

Amp

Remote
Control SMAW
Requires:

Panel Control
SMAW

Select:
Weld

OM-202 137 Page 24

Control

or

Amp

5-4. Lift-Arc Trigger Hold TIG

1

TIG Electrode

Workpiece

. Procedure requires:
control
Start sequence:

Touch

12
Seconds

Touch tungsten electrode to

workpiece at weld start point.
Momentarily depress output
switch.
Slowly lift electrode. An arc will
form when electrode is lifted.

To stop welding, momentarily

depress output switch and output will shut off.
Note: If output switch is momentarily depressed and tungsten is
not touching workpiece:
Do not touch tungsten to work.
Output will shut off in 3 seconds.
Start sequence over.

Do NOT Strike Like A Match!

Ref. S-156 279

OM-202 137 Page 25

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance
!

. Maintain more often

Disconnect power
before maintaining.

during severe conditions.

3 Months
Repair Or
Replace
Cracked
Cables

Replace
Damaged Or
Unreadable
Labels

Replace Cracked
Torch Body

Repair Or Replace
Cracked Cables
And Cords

Clean
And
Tighten Weld
Connections

6 Months
Blow Out Inside

6-2. Blowing Out Inside Of Unit

!

Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow

through front and back louvers as
shown.

ST-801 192

OM-202 137 Page 26

6-3. Voltmeter/Ammeter Help Displays

. All directions are in reference to
the front of the unit. All circuitry
referred to is located inside the
unit.

A
Help 0 Display

HE.L

P0

Indicates a shorted thermistor RT2

on the left side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

Help 1 Display

HE.L

P1

Indicates a malfunction in the primary power circuit. If this display is

shown, contact a Factory Authorized Service Agent.

Help 2 Display

HE.L

P2

Indicates a malfunction in the thermal protection circuitry located on

the left side of the unit. If this display
is shown, contact a Factory Authorized Service Agent.

Help 3 Display

HE.L

P3

Indicates the left side of the unit has

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

Help 4 Display

HE.L

P4

Indicates a malfunction in the thermal protection circuitry located on

the right side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

OM-202 137 Page 27

6-4. Voltmeter/Ammeter Help Displays (Continued)

. All directions are in reference to
the front of the unit. All circuitry
referred to is located inside the
unit.

A
Help 5 Display

HE.L

P5

Indicates the right side of the unit

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

Help 6 Display

HE.L

P6

Indicates that the input voltage is too

low and the unit has automatically
shut down. Operation will continue
when the voltage is within the acceptable lower range limit (15% below the applicable input voltage). If
this display is shown, have an electrician check the input voltage.

Help 7 Display

HE.L

P7

Indicates that the input voltage is too

high and the unit has automatically
shut down. Operation will continue
when the voltage is within the acceptable upper range limit (15%
above the applicable input voltage).
If this display is shown, have an
electrician check the input voltage.
Help 7 can also indicate a bus voltage imbalance.

Help 8 Display

HE.L

P8

Indicates a malfunction in the secondary power circuit of the unit. If

this display is shown, contact a Factory Authorized Service Agent.

Help 9 Display

HE.L

OM-202 137 Page 28

P9

Indicates a shorted thermistor RT1

on the right side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

6-5. Supplementary Protectors

1
2

Supplementary Protector CB1

Supplementary Protector CB2

CB1 protects 110 volt AC portion of

Remote 14 receptacle from overload.
CB2 protects 24 volt AC portion of
Remote 14 receptacle from
overload.
Press button to reset supplementary protector.
1

Ref. ST-801 245-A

6-6. Troubleshooting

Trouble
No weld output; unit completely inoperative.

Remedy
Place line disconnect switch in On position (see Section 4-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-11).
Check for proper input power connections (see Section 4-11).

No weld output; meter display On.

If using remote control, be sure Mode Selector switch is in a position that provides output control at
Remote 14 receptacle.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-4).

Erratic or improper weld output.

Use proper size and type of weld cable (see Section 4-8).
Clean and tighten all weld connections.

No 110 volts AC output at Remote 14

receptacle.

Reset supplementary protector CB1 (see Section 6-5).

No 24 volts AC output at Remote 14

receptacle.

Reset supplementary protector CB2 (see Section 6-5).

OM-202 137 Page 29

SECTION 7 ELECTRICAL DIAGRAM

239 530-B

Figure 7-1. Circuit Diagram For Welding Power Source

OM-180 670 Page 30

Notes

OM-180 670 Page 31

OM-202 137 Page 32

22

60

Figure 8-1. Parts Assembly

59

65

58

57

61

62

56

63

55

64

53

50

52

51

11
12 13

10
14

16

17

18

49

46

15

19

48

45

47

44

20

43

13

21

42
41
40
39

23

22
24

38

37 36

27

26

25

30

11 14

29

28

31
32
33

35

34

SECTION 8 PARTS LIST

802 801-D

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-1. Parts Assembly

. . . 1 . . . . . . . . . . . . . . . 670729 . .
. . . . . . . . . . . . . . . . . . . . . 670737 . .
. . . . . . . . . . . . . . . . . . . . . 670745 . .
. . . 2 . . . . . . . . . . . . . . . 670752 . .
. . . 3 . . . . . . . . . . . . . . . 670760 . .
. . . 4 . . . . . HD1 . . . . . 670778 . .
... 5 ..........................
... 6 ..........................
... 7 ..........................
. . . 8 . . . . . D1,2 . . . . . 639047 . .
. . . 9 . . . . . PC6 . . . . . 670794 . .
. . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . C5,6 R1 . . . . . . . . . . . . . .
. . . 13 . . . . RT1,2 . . . . 670802 . .
. . . 14 . . . . . . . . . . . . . . . 671487 . .
. . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . CB1 . . . . . . . . . . . . . . . .
. . . 18 . . . . . CB2 . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . 670810 . .
. . . 20 . . . . . . . . . . . . . . . 657155 . .
................................
. . . . . . . . . . . . . . . . . . . . . 657163 . .
. . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . 670836 . .
. . . 23 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . PC1 . . . . . 670844 . .
. . . . . . . . . . PLG2 . . . . . . . . . . . . . . .
. . . . . . . . . . PLG3 . . . . . . . . . . . . . . .
. . . . . . . . . . PLG5 . . . . . . . . . . . . . . .
. . . . . . . . . . PLG7 . . . . . . . . . . . . . . .
. . . 25 . . . . RC10 . . . . . . . . . . . . . . .
. . . 26 . . . . . . T2 . . . . . . 670851 . .
. . . 27 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . CT1 . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . C1 . . . . . 670869 . .
. . . 33 . . . . . C3,4 . . . . . 670877 . .
. . . 34 . . . . . PC2 . . . . . 670885 . .
. . . . . . . . . . PLG13 . . . . . . . . . . . . . . .
. . . . . . . . PLG14,21 . . . . . . . . . . . . .
. . . 35 . . . . . . T3 . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . SR1 . . . . . 670893 . .
. . . 40 . . . . PM1,2 . . . . 670901 . .
................................
. . . 40 . . . . PM1,2 . . . . 654186 . .
................................
. . . 41 . . . . . . Z1 . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . L1 . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . T1 . . . . . . . . . . . . . . . . .

Wrapper (ME-175 148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Insulator, Side Rh (ME-175 256) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Insulator, Side Lh (ME-178 551) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Handle (ME-195 585) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Label, Caution Falling Equipment (ME-179 309) . . . . . . . . . . . . . . . . . . . . 2
Transducer, Current 400A (ME-182 918) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bus Bar, Current Sensor (ME-203 342) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bus Bar, Output Rectifier (ME-203 341) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Insulator, Screw (ME-181 853) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit Diode, Ultra Fast Recovery (ME-201 531) . . . . . . . . . . . . . . . . . . . . . . 2
Circuit Card, Filter Board (ME-229 967) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, Mtg Filter Board (ME-187 146) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Snap-In Nyl 1.000 Id X 1.375Mtg Hole (ME-179 276) . . . . . . . 2
Resistor/Capacitor (ME-232 296) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Thermistor, Ntc 30K Ohm (ME-173 632) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Label, Warning Exploding Parts (ME-185 836) . . . . . . . . . . . . . . . . . . . . . 2
Windtunnel, Lh (ME-+183 551) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, 1.000Npt (ME-234 126) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Circuit Breaker, Man Reset 1P 2.5A 250VAC (ME-089 807) . . . . . . . . . . 1
Circuit Breaker, Man Reset 1P 10A 250VAC (ME-083 432) . . . . . . . . . . 1
Panel, Rear (ME-206 460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Strain Relief (ME-213 099) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Flat (ME-198 246) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Pwr 6Mm 4/C 60 (ME-210 346) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, Ident Rear (Order By Model And Serial Number) . . . . . . . . . . . . . 1
Box, Louver (ME-175 138) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bracket, Mtg Contactor/Capacitor/PC Board (ME-192 853) . . . . . . . . . . 1
Circuit Card, Control (ME-229 961) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets (ME-131 056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets (ME-130 203) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets (ME-115 091) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets (ME-115 093) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets (ME-166 679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transformer, Control 420VAC (ME-229 832) . . . . . . . . . . . . . . . . . . . . . . . 1
Windtunnel, Rh (ME-+207 727) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Snap-In Nyl .750 ID x 1.000Mtg (ME-153 403) . . . . . . . . . . . . . 2
Bushing, Snap-In Nyl 1.125Mtg (ME-177 547) . . . . . . . . . . . . . . . . . . . . . 1
Transformer, Current (ME-175 199) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stand-Off, Insul (ME-025 248) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Capacitor, Polyp Film .34Uf 900VDC (ME-186 015) . . . . . . . . . . . . . . . . . 1
Capacitor, Elctlt 2700Uf 450VDC (ME-192 935) . . . . . . . . . . . . . . . . . . . . 2
Circuit Card Assy, Interconnecting W/Cmpnts (ME-256 569) . . . . . . . . . 1
Connector & Sockets (ME-131 204) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets (ME-115 093) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Choke, Common Mode (ME-182 108) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bracket, DI/DT (ME-175 140) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Coil, DI/DT (ME-175 482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Core (ME-109 056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit Diode, Power Module (ME-179 629) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, Transistor IGBT Module (ME-180 110) . . . . . . . . . . . . . . . . . . . . . . . . .
For Serial Number LC358048 and Before . . . . . . . . . . . . . . . . . . . . . . . . . 1
Kit, Transistor IGBT Module (ME-233 043) . . . . . . . . . . . . . . . . . . . . . . . . .
For Serial Number LC358049 and After . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stabilizer (ME-173 570) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Inductor, Input (ME-173 563) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Heat Sink, Power Module (ME-207 725) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transformer, HF (ME-173 811) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-202 137 Page 33

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 8-1. Parts Assembly (Continued)

. . . 45 . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Sink, Rect (ME-207 467) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator, Rectifier (ME-175 255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasket, Di/Dt Rubber (ME-181 197) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . . . . . . . . . . . . Foot, Mtg Unit (ME-229 325) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 48 . . . . . . . . . . . . . . . . . . . . . . . . . . Screw, Mtg Foot (ME-176 736) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 49 . . . . . . . . . . . . . . . 670919 . . Base (ME-175 132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . PC3 . . . . . 670927 . . Circuit Card, Front Panel Display (ME-229 964) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG11 . . . . . . . . . . . . . . . Connector & Sockets (ME-115 091) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . FM . . . . . 670935 . . Motor, Fan 24VDC 3000RPM (ME-175 084) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . RC1 . . . . . 670943 . . Receptacle, W/Leads & Plug (ME-185 730) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal, Connector Friction (ME-178 548) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 54 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . . . 670950 . . Panel, Front (ME-185 732) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . . 670968 . . Receptacle, Twlk Insul Fem (ME-129 525) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 57 . . . . . . . . . . . . . . . 670976 . . Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubing, Gl Acryl .325 (Order By Ft) (ME-070 590) . . . . . . . . . . . . . . . . . . 1ft
. . . . . . . . . . . . . . . . . . . . . 670984 . . Kit, Connection Dinse (ME-145 088) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . . 670992 . . Knob, Pointer .840 (ME-174 992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . . 671008 . . Door, Front (ME-175 855) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . . 671016 . . Knob, Pointer 1.250 (ME-174 991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 61 . . . . . . . . . . . . . . . 671024 . . Insulator, Switch Power (ME-176 226) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . S1 . . . . . 671032 . . Switch, Tgl 3PST 40A 600VAC (ME-244 920) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . L5 . . . . . . . . . . . . . . . . . Core, Toroidal .748 ID X 1.142 OD X .600 Thk (ME-241027) . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Bar, Diode (ME-199 840) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 65 . . . . . . . . . . . . . . . 671040 . . Label, Warning General Precautionary (ME-179 310) . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-202 137 Page 34

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

Unitor ASA
Drammensveien 211
P.O. Box 300 Skoyen
N0212 Oslo
Norway
Tel: +47 22 13 14 15

PRINTED IN USA

201201