Mark VI. Miller. ~ DC-Gas Tungsten Arc. ~ Flux Cored Arc Welding and OWNERS MANUAL. The Power fblue. Description. OM2211B July 1997.

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1 Miller The Power fblue. OM2211B July 1997 En. w/serial Number KH Processes ~ Shielded Metal Arc (Stick) Welding ~ DC-Gas Tungsten Arc (DC-TIG) Welding ~ Flux Cored Arc Welding and Gas Metal Arc Welding (MIG) Spray Transfer with Voltage- Sensing Feeder ~ Air Plasma Cutting and Gouging with Spectrumfi Plus Air Carbon Arc Cutting and Gouging Description Multiple Operator Arc Welding Power Source Mark VI p Visit our website at www~mmerwems.com OWNERS MANUAL

2 some 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 Thats have time to do it any other way. 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 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 will help you protect yourself against potential hazards on the worksite. Weve iie~iiiiiiii p REGISTERED QUALITY SYSTEM made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for reason the unit needs repair, theres a Miller is the first welding equipment manufacturer in the U.S.A. to he registered to the ISO 9001 Quality System Standard. Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. ~ll~ftllh{? Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor call A-Miller. ri/a Miller.. ~

3 SAFETY CONSIGNES READ LIRE Call A-MILLER for your local Miller distributor. Your distributor 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. Miller offers a Technical Manual which provides more detailed seivice and parts information for your unit. To obtain a Technical Manual~ contact your local distributor~ Your distributor can also supply you ~wth Welding Process Manuals suchassmaw, GTAW, GMAW, and GMAW-P For practical information on welding, process applica tions, and Miller products, visit our website at SECTION Symbol Usage TABLE OF CONTENTS PRECAUTIONS Arc Welding Hazards BEFORE USING 1-3. Additional Symbols for Installation, Operation, and Maintenance 1-4. Principal Safety Standards 1-5. EMF Information SECTION 1 DE SECURITE Signification des symboles 1-2. Dangers relatifs au soudage a Iarc AVANT UTILISATION 1-3. Dangers supplømentaires en relation avec Iinstallation, le fonctionnement et Ia maintenance 1-4. Principales normes de søcuritø 1-5. Information sur les champs electromagnetiques SECTION 2 INSTALLATION 2-2. Volt-Ampere Curves 2-3. Duty Cycle And Overheating Standard Module Weld Output Connections Without Common Work Terminal Standard Module Weld Output Connections With Common Work Terminal Parallel Module Weld Output Connections Without Common Work Terminal Parallel Module Weld Output Connections With Common Work Terminal Remote 14 Receptacle Information Electrical Service Guide SECTION 3 OPERATION SECTiON 4MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance 4-3. Troubleshooting SECTION 5 ELECTRICAL DIAGRAM SECTION 6 PARTS LIST OPTIONS AND ACCESSORIES WARRANTY The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW

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5 double-check check bare do SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING som _nd_ Symbol Usage a Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. A Marks a special safety message. ~ Means Note; not safety related. This group of symbols means Waming! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards Arc Welding Hazards I A The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you seethe 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 NO TAG. Read and follow all Safety Standards. A Only qualified persons should install, operate, maintain, and repair this unit. A During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe bums. 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. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR (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 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 conductor first connections. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged wiring can kill. 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 not use work clamp or work cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use onlywell-maintained equipment. Repairor 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 after removal of input power on inverters. Tum 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 =9. 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 exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDS5) 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 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. 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. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-2211 Page 1

6 explosion ARC RAYS can burn eyes and skin BUILDUP OF GAS can Injure or kill Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can bum eyes and skin. Sparks fly oft from the weld. Weara welding helmet fitted with a proper shade of filterto 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 barners to protect others from flash and glare; wam others not to watch the arc. Wear protective clothing made from durable, flame-resistant matenal (leather and wool) and foot protection. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly oft 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, orfire. Check and be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. 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 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. FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw oft slag. Wear approved safety glasses with side shields even under your welding helmet. Shutoff 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. 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. 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,... S S mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by secunng 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 will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings 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 overvalve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-i listed in Safety Standards. CYLINDERS can explode if damaged. OM-2211 Page 2

7 I be 1-3 Additional Symbols for Installation, Operation, and Maintenance I FIRE OR EXPLOSION hazard~ MOVING PARTS can cause injury. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building winng sure power supply system is properly sized, rated, and protected to handle this unit. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. 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. HF. 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 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. 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. 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 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL Safety and Health Standards, OSHA 29 CFR 1910, from Superinten dent of Documents, U.S. Government Printing Office, Washington, D.C Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY Cutting And Welding Processes, NFPA Standard 51 B, from National Fire Protection Association, Batterymarch Park, Quincy, MA OM-2211 Page 3

8 1-5 EMF Information / Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator. magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning Do not coil or drape cables around your body. years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the 4. Keep welding power source and cables as far away from operacommittees judgment, has not demonstrated that exposure to power- tor as practical. frequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as examined. Until the final conclusions of the research are reached, you possible. may wish to minimize your exposure to electromagnetic fields when welding or cutting. About Pacemakers: To reduce magnetic fields in the workplace, use the following Pacemakerwearersconsultyourdoctorfirst. If cleared byyourdoctor, procedures: then following the above procedures is recommended.. OM-2211 Page 4

9 un remplacer VŁrtfier -. SECTION 1 CONSIGNES DE SECURITE - LIRE AVANT UTILISATION som _nd_fre 4/ :Signification des symboies~. a Signifie Mise en garde! Soyez vigilant! Cette procedure presente des risques de danger! Ceux-ci sont identifies par des symboles adjacents aux directives. A Identifie un message de søcuritø particulier. ~ Signifie NOTA nest pas re/at/f a Ia søcuritø. ri~wa Ce groupe de symboles signifie Mise en garde l Soyez vigilant II y a des rtsques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN MOUVEMENTet aux PIECES CFIAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaltre les mesures a prendre pour Łviter tout danger Dangers relatifsau soudage a Iarc A Les symboles prøsentøs ci-aprłs sont utilisøs tout au long du present manuel pour attirer votre attention et identifier lea riaquea de danger. Loraque vous voyez un symbole, soyez vigilant et suivez lea directives mentionnøes atm døviter tout danger. Les consignes de søcuritø presentøes ci-aprłs ne font que røsumer linformation contenue dans lea normes desøcurite enumerøes a Ia section 1-5. Veuillez lire et respecter toutes ces normes de sccuritø. A Linstallation, lutiliaation, lentretien et lea reparations ne doi vent etre confiøs qu des person nes qualif lees. Nutiliser quun materiel en bon Łtat. Reparer ou remplacer sur-le champ les piłces endommagłes. Entretenir lappareil conformement ace manuel. Porter un hamais de securite quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cable de retour de fa on a obtenir un bon contact metal-metal avec Ia piłce ~ souderou Ia table de travail, le plus pits possible de Ia soudure. A Au cours de lutilisation, tenirtoute personne a løcart et plus par ticuliłrement lea enfants. UN CIIOC ELECTRIQUE peut tuer. Isoler Ia pince de masse quand pas mis a Ia piłce pour Łviter le contact avec tout objet motallique. Un simple contact avec des piłces Łlectriques peut provoquer une electrocution ou des blessures graves. LŁlectrode et le circuit de soudage sont sous tension des que lappareil est sur ON. Le circuit dentrłe et les circuits intemes de lappareil sont Łgalement sous tension ace moment-l. En soudage semi-automatique ou automatique, le fil, le dłvidoir, le logement des galets dentratnement et les piłces młtalliques en contact avec le fil de soudage sont sous tension. Des matłriels ma! installłs ou ma! mis a a terre prłsentent un danger. Ne jamais toucher les piłces Łlectriques sous tension. Porter des gants et des vłtements de protection secs ne comportant pas de trous. Sisoler de Ia piłce et de Ia terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empecher le contact phy sique Łventuel avec Ia piłce ou Ia terre. Ne passe servir de source Ølectrique courant Łlectrique dans les zones humides, dans les endroits confines ou l o on risque de tomber. Se servir dune source Łlectrique acourant Łlectrique UNIQUEMENT si le procłdł de soudage le demande. Si lutilisaton dune source Łlectrique acourant Łlectrique savłre nłces saire, se servir de Ia fonction de tłlłcommande Si lappareil en est ØquipŁ. Couperlalimentation ou arrłter le moteur avant de procødera linstal lation, a Ia reparation ou a lentretien de lappareil. DŁverrouiller lalimentation selon Ia norme OSHA 29 CFR (voir normes de słcuritł). Installeret mettre a laterre correctement cet appareil conformłment a son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. Toujours verifier Ia terre du cordon dalimentation et sassu rer que le fil de terre du cordon dalimentation est bien raccordł a Ia bome de terre du sectionneurou que Ia fiche du cordon est raccordłe a une prise correctement mise a Ia terre. En effectuant les raccordements dentrłe fixer dabord le conducteur de mise a Ia terre approprtł et contre-vłrifier les connexions. VŁrifierfrŁquemment le cordon dalimentation pour voir sil nest pas endommagł ou dłnudł le cordon immłdiatement sil est endommagł cable dłnudł peut provoquer une electrocution. Mettre lapparei! hors tension quand on ne lutilise pas. Ne pas uti!iser des cables uses, endommagłs, de grosseur insuffi sante ou mal ŁpissŁs. Ne pas enrouler les cables afflour du corps. Si Ia piłce soudłe dolt Łtre mise a laterre, le faire directementavec un cable distinct ne pas utiliser le connecteur de piłce ou le cable de retour. Ne pas toucher lelectrode quand on est en contact avec Ia piłce, Ia terre ou une electrode provenant dune autre machine. Ily a DU COURANT CONTINU IMPORTANT dans les convertisseurs aprłs Ia suppression de Ialimenta tion Ølectrique. ArrŁter les convertisseurs, dłbrancher le courant electrique, et de charger les condensateurs dalimentation selon les instructions indiqułes dans Ia partie entretien avant de toucher les piłces. J~~ V LES FUMEES ET LES GAZ peuvent Œtre dangereux. Le soudage genłre des fumłes et des gaz. Leur inhalation peut Łtre dangereux pour votre sante. Eloigner votre tœte des fumłes. Ne pas respirer les fumees. A lintłrieur, ventiler Ia zone et/ou utiliser un echappement au ni veau de arc pour lłvacuation des fumłes et des gaz de soudage. Si Ia ventilation est insuffisante, utiliser un respirateur a alimenta tion dair homologue. Lire les specifications de słcuritł des materiaux (MSDSs) et les ins tructions du fabricant concemant les młtaux, les consommables, les revłtements, les nettoyants et les degraisseurs. Travailler dans un espace fermł seulement sii est bien ventilł ou en portant un respirateura alimentation dair. Demander toujours a un surveillant d ment forme de se tenir a proximitł. Des fumøes et des gaz de soudage peuvent dłplacer lair et abaisser le niveau doxygłne provoquant des blessures ou des accidents models. Sassurer que Iair de respiration ne presente aucun danger. Ne pas souderdans des endroits situes a proximite dopłrations de degraissage, de nettoyage ou de pulvłrisation. La chaleur et les rayons de Iarc peuvent rłagir en presence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des młtaux munis dun revœtement, tels que lacier galvanisø, plaque en plomb ou au cadmium a moms que le revłte ment nail ŁtŁ enlevł dans Ia zone de soudure, que lendroit soit bien ventilø, et si necessaire, en portant un respirateur a alimenta tion dair. Les revłtements et tous les metaux renfermant ces ele ments peuvent dłgager des tumees toxiques en cas de soudage. OM-2211 Page 5

10 risque LESRAYONSDEL!ARC peuvent pro~ voquer desbr lures:danł les yeux et sur Ia peau Le rayonnement de larc du procedø de soudage genore des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des bri~iures dans les yeux et sur Ia peau. Des etincelles sont projetees pendant 0 soudage. Porter un casque de soudage muni dun Øcran de filtre appropnø pour proteger votre visage et vos yeux pendant le soudage ou pour regar der (voir ANSI Z49. 1 et Z87.1 ØnumØrØ dans les normes de søcuntø). Porter des protections approuves pour les oreilles Si le niveau sondre est trop ØlevØ. Utiliser des Øcrans ou des barnłres pour protegerdes tiers de IØclair et de IØblouissement; demander aux autres personnes done pas re garder arc. Porter des vøtements do protection constituø dans une matiłre dura ble, resistant au feu (cuir ou lame) et une protection des pieds. (~ m~ LESOUDAGE peutprovoquør incendie ou ne explosion. Le soudage effectuø sur des conteneurs fermøs tels que des reservoirs, tambours ou des conduites peut provoquerleureclatement. Des etincellespeuventœtre m E~I projetøes de arc de soudure. La projection døtincel es, des piłces chaudes et des equipements chauds peut provoquerdes incendies et des brolures. Le contact accidentel de lølectrode avec des objets metalliques peut provoquer des Øtincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vønfier et sassurer que lendroit ne prøsente pas de danger. Se proteger et dautres personnes de Ia projection døtincelles et de metal chaud. No pas souder dans un endroit l o des Øtincelles peuvent tomber sur des substances inflammables. DØplacertoutes les substances inflammables a une distance de 10,7 m de larc do soudage. En cas dimpossibilitø les recouvrirsoigneuse ment avec des protections homologues. Des Øtincelles et des matønaux chauds du soudage peuvent facile ment passer dans dautres zones en traversant de petites fissures et des ouvertures. Surveillertout døclenchement dincendie et tenir un extincteur proxi mite. Le soudage effectuø sur un plafond, plancher, paroi ou separation peut dłclencher un incendie de lautre cotø. Ne pas effectuer le soudage sur des conteneurs fermøs tels que des reservoirs, tambours, ou conduites, a moms quils naient ØtØ prøpa res correctement conforrnøment a AWS F4.1 (voir es norrnes de securite). Brancher le cable sur Ia piłce le plus prłs possible do Ia zone de sou dage pour Oviter le transport du courant sur une longue distance par des chemins inconnus eventuels en provoquant des nsques dølec trocution et dincendie. Ne pas utiliser le poste de soudage pour degeler des conduites go lees. En cas de non utilisation, enlever Ia baguette dølectrode du porte electrode ou couper le fil a Ia pointe de contact. Porter dos vœtements de protection døpourvus dhuile tels que des gants en cuir, une chemise en matønau lourd, des pantalons sans re vers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible de vos poches telles quun allumeur au butane ou des allumettes. Le soudage, løcaillement, le passage de Ia piłce a Ia brosso en fil de for, et le meulage generent desłtincelles et des particules metalliques volan tes. Pendant Ia penode do refroidissement dos soudures, elles nsquent de projeter du laitier. DES PARTICULES VOLANTES peuvent blesser les yeux. Porter des lunettes do søcuritø avec ecrans latøraux ou un Øcran facial. LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou mœmeiafl~orl::. ( ) U L~ Fermer Ialimentation du gaz protecteur en cas do non utilisation. Veillertoujours a bien aører los espacesconfinøs ou so servir dun respi rateur dadduction dair homologue. DES PIECESCHAUDES peuvent pro voquer des~bru1ures graves. No pas toucher des parties chaudes a mains flues PrØvoir une periode de refroidissement avant dutiliser le pistolet ou Ia torche. LES CHAMPS MAGNETIQUES peuvent affecter les stimulateurs cardiaques. Los porteurs dun stimulateur cardiaque doivent dabord consultor leur medecin avant de sapprocher des operations do soudage a larc, do gougeago ou do soudago par points. LE BRUIT peut affecter louie. Le bruit dos procossus ot dos equipements pout affecter louie. Porter des protections approuves pour los oreilles Si 10 nivoau sondro ost trop ØlevØ. Si des BOUTEILLES sont endomma gees, elles pourront exploser. Des bouteilles do gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endomma gee,ellopoutexplosor. Dufaitquelesbouteillesdegaz font normalement partie du procede do soudago, es manipuler avec precaution. Proteger les bouteillos do gaz compnme dune chaleur excessive, des chocs mecaniques, du laitier, des flammes ouvertes, des Øtin cellos et des arcs. Placer les bouteilles debout en les fixant dans un support station nairo ou dans un porte-bouteilles pour los ompœchor do tombor ou do so renverser. Tenir los bouteilles eloignees des circuits de soudago ou autros cir cuits electriques. Ne jamais placer une torcho do soudage sur uno bouteille a gaz. Une electrode do soudage no dolt jamais entrer en contact avec une boutoillo. No jamais souder uno bouteille pressurisee dexplosion. Utiliser seulement des bouteilles do gaz protectour, regulateurs, tuyaux et raccords convenables pour cello application specifique; los maintenir ainsi quo les elements associøs en bon Øtat. Ne pas tonir Ia tœte en face do Ia sortie en ouvrant Ia soupape do Ia bouteillo. Maintenir 10 chapeau de protection sur Ia soupape, dutilisation ou do branchoment do Ia boutoille. Porteurs do stimulateurcardiaque, rostez a distance. sauf en cas Lire et suivre los instructions concemant les bouteilles de gaz corn prime, los equipements associøs et los publications P-i CGA Ønu mørøos dans los nomios do søcuntø.. OM-2211 Page 6

11 sassurer 1-3. Dangers supplømentaires en relation avec linstallatiofl; le fonctionnement et Ia maintenance Risque DINCENDIE OU DEXPLOSION. Ne pas placer appareil sur, au-dessus ou a proximite de surfaces infllammables. Ne pas installer lappareil a proximitø de produits inflammables Ne pas surcharger linstallation electnque que lalimen tation est correctement dimensionnø et protøgø avant de mettre lappareil en service. LA CHUTE DE LAPPAREIL petit blessør. Utiliserlanneau de levage uniquement pour sou lever lappareil, NON PAS les chariot, les bouteil es de gaz ou tout autre accessoire. Utiliser un engin dune capacite approp nøe pour soulever lappareil. En utilisant des fourchøs de levage pour døplacer lunitø, sassurer que les fourches sont suffisamment longues pourdøpasserdu c tø oppose de Iappareil. LEMPLOI EXCESSIF peut SURCHAUFFER LEQU!PEMENT. PrØvoir une penode de refroidissement, respec ter le cycle opøratoire nominal. Reduire le courantou le cycle opøratoire avant de recommancer le soudage. Ne pas obstruer les passages dair du poste. LES CHARGES ELECTROSTATIQUES peuvent endommager les circuits im~ primes. Etablir Ia connexion avec Ia barrette de terre avant de manipuler des caries ou des piłces. Utiliser des pochettes et des boites antistatiques pour stocker, deplacer ou expedier des caries de circuits impnmes. DES ORGANES MOBILES peuvent provoquerdes 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 pro voquer des blessures. Ne pas appuyer sur Ia gachette avant den avoir recu linstruction. Ne pas dinger le pistolet vers soi, dautres per sonnes ou toute piłce mecanique en engagearri le fil de soudage. DES ORGANES MOBILES: peuvent provoquer des blessures. Rester a lecart des organes mobiles comme le ventilateur. Maintenirfermes et fixement en place es portes, panneaux, recouvrements et dispositifs de protection. LE RAVONNEMENT HAUTE FRE QUENCE(H.F.) risque de provoquer des iliterførences. Le rayonnement haute frequence peut provoquer des interferences avec les equipements de ra dionavigation et de communication, les services de søcuritø et les ordinateurs. Demander seulement a des personnes qualifiees familiansøes avec des Øquipements electroniques de faire fonctionner installa tion. Lutilisateur est tenu de faire cornger rapidement par un Ølectncien qualifie les interferences resultant de linstallation. Si le FCC signale des interferences, arrøter immødiatement lappa reil. Effectuer regulierement le controle et lerrtretien de linstallation. Maintenir soigneusement fermøs les portes et les panneaux des sources de haute frequence, maintenir les Øclateurs a une distance correcte et utiliser une terre et et un blindage pour røduire les inter førences Oventuelles. LE SOUDAGE A L~ARC risque de provoquer des interferences. LØnergie electromagnetique risque de provoquer des interferences pour løquipement electronique sensible tel que les ordinateurs et lequipement commandø par ordinateur tel que les robots. Veiller ace que tout lequipement de Ia zone de soudage soit com patible electromagnøtiquement. Pour røduire Ia possibilitø dinterførence, maintenir les cables de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller a souder a une distance de 100 metres de tout equipement electronique sensible. Veiller a ce que ce poste de soudage soit pose et mis a Ia terre conformement a ce mode demploi. En cas dinterførences aprłs avoir pns es mesures prøcødentes, il incombe a lutilisateur de prendre des mesures supplømentaires telles que le deplacement du poste, lutilisation de cables blindøs, lutilisation de filtres de ligne ou Ia pose de protecteurs dans Ia zone de travail. LES CHAMPS MAGNETIQUES peuvent affecterles stimulateurs cardiaques. Porteurs de stimulateur cardiaque, restez a dis tance. Les porteurs dun stimulateur cardiaque doivent dabord consutter leur mødecin avant de sapprv cher des operations de soudage a larc, de gou geage ou de soudage par points. OM-2211 Page 7

12 1-4 Principales normes de søcuritø Safety in Weldingand Cuffing, norme ANSI Z49.i, delamencan Welding Society, 550 N.W. Lejeune Rd, Miami FL Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Govemment Printing Office, Washington, D.C Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances, nomie AWS F4.1, de American Welding Society, 550 N.W. Lejeune Rd, Mia mi FL National Electrical Code, NFPA Standard 70, de Ia National Fire Pro tection Association, Batterymarch Park, Quincy, MA Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA Regles de søcuntø en soudage, coupage etprocødes connexes, norme CSA Wi 17.2, de Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1 R3. Safe Practices For Occupation And Educational Eye And Face Protec tion, norme ANSI Z87.1, de American National Standards Institute, 1430 Broadway, New York, NY Cuffing and Welding Processes, nomie NFPA 51 B, de Ia National Fire Protection Association, Batterymarch Park, Quincy, MA Information sur tes champs ØtectromagnØtiques DonnØes sur le soudage electnque et sur les effets, pour lorganisme, Afin de røduire les champs electromagnetiques dans environnement des champs magnetiques basse frequence de travail, respecter les consignes suivantes Lextrait suivant est tire des conclusions gønørales du document intitu lø Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper; OTABPE53 (Washington DC: U.S. Govern ment Printing Office, mai 1989), publie par le Office of Technology Assessment du Congres amøricain : i. ii existe maintenant dabon dantes donnøes scientifiques compiløes a Ia suite dexpønences sur Ia cellule ou døtudes sur des animaux et des humains, qui montrent clairementqueleschampselectromagnetiques bassefrequence peu vent avoir des effets sur lorganisme et mœme y produire des transformations. MŒme sil sagit de travaux de trłs grande qualite, les røsultats sont complexes. Cette dømarche scientifique ne nous permet pas døtablir un tableau densemble coherent. Pire encore, elle ne nous permet pas de tirer des conclusions finales concemant les ns ques Øventuels, ni doffrir des conseils sur les mesures a prendre pour røduire sinon Øliminer les risques Øventuels. (Traduction libre) 1 Garder les cables ensembles en les torsadant ou en les attachant avec du ruban adhøsif. 2 Mettre tous les cables du c tø oppose de lopørateur. 3 Ne pas courber pas et ne pas entourer pas les cables autour de vous. 4 Garder le poste de soudage et les cables le plus loin possible de vous. 5 Relier Ia pince de masse le plus pres possible de Ia zone de soudure. Consignes relatives aux stimulateurs cardiaques Les consignes mentionnøes prøcedemment font parlie de celles desti nøes aux personnes ayant recours a un stimulateur cardiaque. Veuillez consulter votre mødecin pour obtenir plus de details. OM-2211 Page 8

13 SECTION 2-INSTALLATION 2-1. Specifications Rated Output at 44 Volts DC DC Welding Current Range, Single Module Max. Open Circuit Voltage Amps Input at Rated Output of 750 A, 60 Hz, Three-Phase 230 V 460 V 575 V KVA KW Single Module I Main Transformer 250 A at 60% 1500 A at 25% I 750 A at 100% Duty Cycle Duty Cycle Duty Cycle I 82.5 I 6.2 I ~ While idling 2-2. Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output ca pabilities of the welding power source. Curves of other settings fall between the curves shown. (I) I! DC AMPERES SB OM-2211 Page 9

14 60% 100% 25% And Overheatii ~ Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. A Exceeding duty cycle can damage unit and void warranty ~ 500 ~ The main transformer of the poly weld system has dual duty cycle ratings, each for a specific amper age output range. If the unit is oper ated in the 750 ampere range, the unit is rated at 100% duty cycle. This means the polyweld system can be operated at 750 amperes X DUTY CYCLE continuously. When the unit is op erated in the 1500 ampere range, it is rated at 25% duty cycle. Main Transformer Duty Cycle at 750 Amperes The sum of the outputs of each module should not exceed the rated duty cycle of the main trans former. For example, the polyweld Main Transformer Continuous Welding Duty Cycle at 1500 Amperes system can be safely operated at a load of 1000 amperes at 80 per cent duty cycle. This value could be obtained by operating four mod ules at a load of 250 amperes at 80 percent duty cycle, or by operating six modules at a load of 167 amperes at 80 percent duty cycle. 2-1/2 Minutes Welding 7-1/2 Minutes Resting Single Module Duty Cycle at 250 Amperes 6 Minutes Welding 4 Minutes Resting Overheating Minutes OM-2211 Page 10

15 Movement 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device A High center of gravity always securelytie down unit with ade quate chains or other proper re straints when moving to pre vent tipping. Do not place unit where it could tip. Locate unit near correct input pow er supply. Location Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 orcec Section in (920mm) AirOut IMPORTANT! This unit contains fan blades with different airflow directions to provide proper cooling of components. Consult Owners Manual for correct Part No. and location. S-i Do not block airflow to sides of unit. bc_i 3/96 Ret. ST-801 OM-2211 Page 11

16 Dimensions And Weights Dimensions F.Ieight I 65 in (1651 mm) Width I 56-3/4 in (1442 mm) Depth 34-1/4 in (870 mm) 72 in (1829 mm) with lifting eye Weight Single Module I Unit 125 lb (57 kg) 1825 lb (828 kg) Volts AC GFCI Receptacles And Circuit Breakers!1~H 1 115V15AACGFCI Receptacles RC9 And RC1O These receptacles supply up to 15 amperes of 115 volts ac power. If a ground fault is detected, the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment. Check for dam aged tools, cords, plugs, etc. con nected to the receptacle. Press button to reset receptacle and resume operation. H ~ H H ~ H properly ~ At least onceamonth, test but ton to verify GFCI is working,, Circuit Breaker CB1 CB1 protects RC9 from overload. If 0 ~ 0 ~ CB1 opens, no output is available ~ CB2 ~~/ RC from RC9. 3 Circuit Breaker CB2 protects RC1O from overload. If CB2 opens, no output is available from RC1O. 4 Circuit Breaker CB3 CB3 protects the 115 volts ac portion of Remote 14 receptacle from overload. 5 CB4 CB4 protects the 24 volts ac portion of Remote 14 receptacle RC8 from overload. Press button to reset breaker. Ref. ST OM-2211 Page 12

17 2-7. Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or LeSS 150ft (45 m) 200 ft (60 m) 250ft (70 m) 300ft (90 m) 350ft (105 m) 400ft (120 m) Welding Amperes 10 60% Duty Cycle % Duty Cycle 10100% Duty Cycle /0 1/ /0 2/0 3/0 3/ /0 2/0 3/0 4/0 4/ /0 2/0 3/0 4/ / /0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/ /0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/ /0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/ /0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/ /0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/ /0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/ / /0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/ /0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/ /0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/ /0 2-4/0 3-3/0 4-3/0 4-4/ /0 3-3/0 3-4/0 4-4/ Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes Common Work Cable Sizes Common Work Cable Sizes At Main Transformer Rated Welding Current Cable Length 50ft(15m) looft(30.5m) 150ft(46m) 200ft(61 m) Cable Size 2No.3/0 2No.4/0 3No.3/0 3 No.4/0 OM-2211 Page 13

18 2-9. Safety Information For Connecting To Weld Output Terminals ri~ A ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections. Turn Oft welding power source before making any weld output connections.. Do not connect welding output of difterent polarities to the same structure. See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart 0 (addresses at beginning of manual). When Positive or Negative weld output terminal is jumper linked to the Common Work terminal and the work cable is connected to the Common Work Connection panel, do not connect a cable between the remaining weld output terminal and the work. Remove jumper link from any module where work and electrode connections are made directly to the Positive and Negative output terminals. Do not handle or come in contact with two live electrodes at the same time. Connect all paralleled modules for the same polarity. ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS exist between electrode holders of opposite polarity. Do not touch electrode holders of opposite polarity at the same time. V Separate electrode holders of opposite polarity to prevent contact. Consult ANSI Z49.1 for common grounding safe practices Weld Output Terminals A Read and understand safety information in Section 2-9 before proceeding. 1 Handle 2 Positive (+) Weld Output Terminal 3 Negative () Weld Output Terminal 4 Weld Output Terminal Cover (Typical For All Weld Output Terminals) Cover all weld output terminals with weld output terminal covers. Go to Section 2-11 and/or 2-12 for standard module weld output con nections, or Section 2-13 and/or 2-14 for parallel module weld output connections. Ref. ST OM-2211 Page 14

19 2-11. Standard Module Weld Output Connections Without Common Work Terminal A Read and understand safety information in Section 2-9 before proceeding. See Section 2-7 for proper cable size. 1 Electrode Holder Cable 2 Work Cable For Electrode Positive (Reverse Polarity/DCEP), connect work cable to Negative () terminal and electrode holder cable to Positive (+)tem,inal (see Section 2-10). For Electrode Negative (Straight Polarity/DCEN), reverse cable connections. 3 Weld Output Terminal Cover (Typical For All Weld Output Terminals) Cover all weld output terminals with weld output terminal covers. 2 Tools Needed: ~ 3/4,7/8 in Ret. ST OM-2211 Page 15

20 2-12. Standard Module Weld Output Connections With Common Work Terminal A INADEQUATE WORK CABLE CONNECTIONS can cause serious damage to input power service and create a hazardous condition. Connect a weld cable of adequate size between the Com mon Work Connection and the workpiece whenever any module(s) is connected to use the Common Work terminal. Do not exceed duty cycle of machine. A Read and understand safety information in Section 2-9 before proceeding. See Section 2-7 for proper cable size. 1 Electrode Holder Cable 2 Work Jumper Cable 3 Common Work Terminal 4 Common Work Cable For Electrode Positive (Reverse Polarity/DCEP), connect work jumper cables from Negative () terminals to Common Work termi nal, and connect electrode holder cables to Positive (+) terminals (see Section 2-10). For Electrode Negative (Straight Polanty/DCEN), connect work jumper cables from Positive (+) ter minals to Common Work terminal, and connect electrode holder cables to Negative () terminals (see Section 2-10). Connect as many modules as re quired. Do not exceed duty cycle of machine. 5 Cable Restraint Route cables through restraints as shown. 6 Weld Output Terminal Cover (Typical For All Weld Output Terminals) Cover all weld output terminals with weld output terminal covers... For common work connection, work cable must be able to carry combined weld outputof all modules using the Common Work Terminal (see Section 2-8 forprop er cable size). The Common Work Terminal is isolated from the unit frame. Tools Needed: -r 3/4,7/8 in Ref. ST OM-2211 Page 16

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