Miller Syncrowave 250dx

OM-359
196 831N
March 2003
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Syncrowave 250 DX
And Non-CE Models
Visit our website at
www.MillerWelds.com
From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you dont have time to do
it any other way.
Thats why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldnt afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
Weve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Working as hard as you do

every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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 orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
The following terms are

used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
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. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
5
SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
11
SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Automation 10-Pin Connection (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . .
3-10. TIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . .
3-12. Front Panel Display For TIG AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . .
3-15. Front Panel Display For Stick AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
13
13
15
16
17
17
18
19
19
20
22
25
26
28
30
31
32
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (Requires
. . . . Optional Sequence Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting TIG Starting Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Amperage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Pulse Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Final Slope Control And Final Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
35
35
35
36
7
8
8
38
40
42
44
45
45
46
48
50
51
52
53
54
(Continued)
TABLE OF CONTENTS
4-19. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
55
56
SECTION 5 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
58
58
59
60
61
SECTION 6 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
SECTION 7 HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
63
63
64
SECTION 8 SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC

. . . . . . . OR AC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)
8-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
65
66
SECTION 9 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
67
68
69
SECTION 10 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
OPTIONS AND ACCESSORIES

WARRANTY
Declaration of Conformity For

European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturers Name:
Manufacturers Address:
Declares that the product:
1635 W. Spencer Street

Appleton, WI 54914 USA
Syncrowave 250DX
conforms to the following Directives and Standards:

Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 609741
(November 1997 Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1_11/02
Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_7/02
1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means Note; not safety related.
This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.
Y Only qualified persons should install, operate, maintain, and

repair this unit.
D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.
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 electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
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 Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not 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 drape cables over your body.
FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
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 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-359 Page 1
ARC RAYS can burn eyes and skin.

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

D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-359 Page 2
D Pacemaker wearers keep away.

D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.

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

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and 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 Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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 Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
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.
STATIC (ESD) can damage PC boards.

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 cause injury.

D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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-359 Page 3
1-4. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:

8004636727 or in Toronto 4167474044, website: www.csainternational.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 100368002 (phone: 2126424900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (phone: 6177703000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:
6177703000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 222024102 (phone: 7034120900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
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 (there
are 10 Regional Officesphone for Region 5, Chicago, is
3123532220, website: www.osha.gov).
1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-359 Page 4
1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 CONSIGNES DE SCURIT LIRE AVANT

UTILISATION
som _nd_fre 7/02
1-1. Signification des symboles

Signifie Mise en garde. Faire preuve de vigilance.
Cette procdure prsente des risques identifis par les
symboles adjacents aux directives.
Y Identifie un message de scurit particulier.
. Signifie NOTA ; nest pas relatif la scurit.
Ce groupe de symboles signifie Mise en garde. Faire preuve de vigilance. Il y a des dangers lis aux CHOCS LECTRIQUES, aux
PICES EN MOUVEMENT et aux PICES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.
1-2. Dangers relatifs au soudage larc

Y Les symboles ci-aprs sont utiliss tout au long du prsent
manuel pour attirer lattention sur les dangers potentiels et les
identifier. Lorsquon voit un symbole, faire preuve de vigilance et
suivre les directives mentionnes afin dviter tout danger. Les
consignes de scurit nonces ci-aprs ne font que rsumer le
contenu des normes de scurit mentionnes la section 14.
Lire et respecter toutes ces normes.
D Nutiliser que du matriel en bon tat. Rparer ou remplacer surle

champ les pices endommages. Entretenir lappareil conformment
au prsent manuel.
Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies.
D Fixer le cble de retour de faon obtenir un bon contact mtal sur

mtal avec la pice souder ou la table de travail, le plus prs possible
de la soudure.
Y Pendant lutilisation de lappareil, tenir lcart toute personne,

en particulier les enfants.
D Porter un harnais de scurit quand on travaille en hauteur.

D Maintenir solidement en place tous les panneaux et capots.
Ne pas connecter plus dune lectrode ou plus dun cble de masse un

mme terminal de sortie.
LES DCHARGES LECTRIQUES

peuvent tre mortelles.
Un simple contact avec des pices sous tension peut
causer une lectrocution ou des blessures graves.
Llectrode et le circuit de soudage sont sous tension
ds que lappareil est en fonctionnement. Le circuit
dentre et les circuits internes de lappareil sont galement sous tension.
En soudage semiautomatique ou automatique, le fil, le dvidoir, le
logement des galets dentranement et les pices mtalliques en contact
avec le fil de soudage sont sous tension. Tout matriel mal install ou mal
mis la terre prsente un danger.
D Ne jamais toucher aux pices lectriques sous tension.
D Porter des gants et des vtements de protection secs et exempts de
trous.
D Sisoler de la pice et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empcher tout contact
physique avec la pice ou la terre.
D
D
D
Ne pas se servir dune source de courant alternatif dans les zones humides, les endroits confins ou l o on risque de tomber.
Ne se servir dune source de courant alternatif QUE si le procd de soudage lexige.
Si lutilisation dune source de courant alternatif savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip.
D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Couper/tiqueter
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de scurit).
D Installer et mettre la terre correctement lappareil conformment
son manuel dutilisation et aux codes nationaux, provinciaux et
municipaux.
D 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.
D Pour excuter les branchements dentre, fixer dabord le conducteur
de mise la terre adquat et contrevrifier les connexions.
D Vrifier frquemment le cordon dalimentation et sassurer quil nest
ni endommag ni dnud ; le remplacer immdiatement sil est endommag tout cble dnud peut causer une lectrocution.
D Mettre lappareil hors tension quand on ne lutilise pas.
D Ne pas utiliser de cbles uss, endommags, de calibre insuffisant ou
mal pisss.
D Ne pas senrouler les cbles autour du corps.
D Si la pice soude doit tre mise la terre, le faire directement avec un
cble distinct.
D Ne pas toucher llectrode quand on est en contact avec la pice, la
terre ou une lectrode dune autre machine.
Il subsiste un COURANT CONTINU IMPORTANT

dans les convertisseurs aprs la suppression de
lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique et dcharger les condensateurs dalimentation selon les instructions
nonces la section Entretien avant de toucher les pices.
LES FUMES ET LES GAZ peuvent

tre dangereux.
Le soudage gnre des fumes et des gaz dont
linhalation peut tre dangereuse pour la sant.
D Se tenir distance des fumes et ne pas les inhaler.

D lintrieur, ventiler la zone et/ou utiliser un dispositif daspiration au
niveau de larc pour lvacuation des fumes et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur adduction
dair agr.
D Lire les fiches techniques de santscurit (FTSS) et les instructions du fabricant concernant les mtaux, les consommables, les
revtements, les nettoyants et les dgraisseurs.
D Ne travailler dans un espace clos que sil est bien ventil ou porter un
respirateur adduction dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage
peuvent se substituer lair, abaisser la teneur en oxygne et causer
des lsions ou des accidents mortels. Sassurer que lair est respirable.
D Ne pas souder 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 de mtaux munis dun revtement, tels que la tle
dacier galvanise, plombe ou cadmie, moins que le revtement
nait t enlev dans la zone de soudage, que lendroit soit bien ventil, et si ncessaire, porter un respirateur adduction dair. Les
revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques lorsquon les soude.
OM-359 Page 5
LES RAYONS DE LARC peuvent causer des brlures oculaires et cutanes.

Le rayonnement de larc gnre des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brlures oculaires et cutanes.
Des tincelles sont projetes pendant le soudage.
D Porter un masque de soudage muni dun filtre de la nuance adquate
pour se protger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de scurit ANSI Z49.1 et Z87.1).
D Porter des lunettes de scurit crans latraux sous le masque.
D Utiliser des crans ou des barrires pour protger les tiers de lclat
blouissant ou aveuglant de larc ; leur demander de ne pas regarder
larc.
D Porter des vtements de protection en matire durable et ignifuge
(cuir ou laine) et des chaussures de scurit.
LE SOUDAGE peut causer un incendie ou une explosion.

Le soudage effectu sur des rcipients ferms tels que
des rservoirs, des fts ou des conduites peut causer
leur clatement. Des tincelles peuvent tre projetes
de larc de soudure. La projection dtincelles, les
pices chaudes et les quipements chauds peuvent causer des
incendies et des brlures. Le contact accidentel de llectrode avec tout
objet mtallique peut causer 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 Se protger et protger les tiers de la projection dtincelles et de mtal chaud.
D Ne pas souder un endroit o des tincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables une distance de 10,7 m
de larc de soudage. En cas dimpossibilit, les recouvrir soigneusement avec des protections agres.
D Des tincelles et des matires en fusion peuvent facilement passer
mme par des fissures et des ouvertures de petites dimensions.
D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.
D Le soudage effectu sur un plafond, un plancher, une paroi ou une
cloison peut dclencher un incendie de lautre ct.
D Ne pas souder des rcipients ferms tels que des rservoirs, des fts
ou des conduites, moins quils naient t prpars conformment
lAWS F4.1 (voir les normes de scurit).
D Brancher le cble sur la pice le plus prs possible de la zone de soudage pour viter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques dlectrocution 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 porte
lectrode ou couper le fil au raz du tubecontact.
D Porter des vtements de protection exempts dhuile tels que des
gants en cuir, une chemise en tissu pais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
quun briquet au butane ou des allumettes.
LES PARTICULES PROJETES peuvent blesser les yeux.

D Le soudage, le burinage, le passage de la pice
la brosse mtallique et le meulage provoquent
lmission dtincelles et de particules mtalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de scurit crans latraux agrs, mme sous le

masque de soudage.
OM-359 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou mme

la mort.
D
Couper lalimentation en gaz protecteur en cas de

non utilisation.
Veiller toujours bien ventiler les espaces confins ou porter un respirateur adduction dair agr.
LES PICES CHAUDES peuvent causer des brlures graves.

D Ne pas toucher les pices chaudes main nue.
D Prvoir une priode de refroidissement avant
dutiliser le pistolet ou la torche.
LES CHAMPS MAGNTIQUES peuvent

perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque

doivent se tenir distance.
Ils doivent consulter leur mdecin avant de sapprocher dun lieu o on excute des oprations de soudage larc, de gougeage ou de soudage par points.
LE BRUIT peut affecter loue.

Le bruit de certains processus et quipements peut
affecter loue.
D
Porter des protecteurs doreille agrs si le niveau

sonore est trop lev.
Les BOUTEILLES
peuvent exploser.
endommages
Les bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Toute bouteille endommage
peut exploser. Comme les bouteilles de gaz font
normalement partie du procd de soudage, les
manipuler avec prcaution.
D Protger les bouteilles de gaz comprim de la chaleur excessive, des
chocs mcaniques, du laitier, des flammes nues, des tincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un portebouteilles 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 poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une lectrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression elle
risquerait dexploser.
D Nutiliser que les bouteilles de gaz protecteur, rgulateurs, tuyaux et
raccords adquats pour lapplication envisage ; les maintenir en bon
tat, ainsi que les pices connexes.
D Dtourner la tte lorsquon ouvre la soupape dune bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publications P1 de la CGA,
mentionnes dans les normes de scurit.
1-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de

lappareil.
Risque DINCENDIE OU DEXPLOSION
LES ORGANES MOBILES peuvent

causer des blessures.
D Ne pas placer lappareil sur une surface inflammable, ni audessus ou proximit delle.
D Se tenir lcart des organes mobiles comme les

ventilateurs.
D Maintenir ferms et bien fixs les portes,
panneaux, recouvrements et dispositifs de
protection.
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 LAPPAREIL peut

blesser.
D Nutiliser que lanneau de levage pour lever lappareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacit adquate pour lever
lappareil.
D Si on utilise un chariot lvateur pour dplacer lunit, sassurer que
les fourches sont suffisamment longues pour dpasser du ct oppos de lappareil.
LEMPLOI EXCESSIF peut FAIRE

SURCHAUFFER LQUIPEMENT.
D Prvoir une priode de refroidissement ; respecter le cycle opratoire nominal.
D Rduire le courant ou le cycle opratoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer lalimentation en air du poste.
LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D Mettre un bracelet antistatique 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 imprims.
LES PICES MOBILES peuvent causer des blessures.

D Se tenir lcart des pices mobiles.
D Se tenir lcart des points de coincement tels
que les dvidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.

D Ne pas appuyer sur la gchette avant den avoir
reu linstruction.
D Ne pas diriger le pistolet vers soi, vers dautres
personnes ou vers toute pice mcanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRQUENCE (H. F.) risque de causer des

interfrences.
D Le rayonnement haute frquence peut causer
des interfrences avec les quipements de radionavigation et de communication, les services de
scurit et les ordinateurs.
D Ne demander qu des personnes qualifies familiarises avec les
quipements lectroniques de faire fonctionner linstallation.
D Lutilisateur est tenu de faire corriger rapidement par un lectricien
qualifi les interfrences causes par linstallation.
D Si la Federal Communications Commission signale des interfrences, arrter immdiatement lappareil.
D Faire rgulirement contrler et entretenir linstallation.
D Maintenir soigneusement ferms les panneaux et les portes des sources de haute frquence, maintenir le jeu dclatement au rglage
adquat et utiliser une terre et un blindage pour rduire les interfrences ventuelles.
LE SOUDAGE LARC peut causer

des interfrences.
D Lnergie lectromagntique peut causer des
interfrences avec lquipement lectronique
sensible tel que les ordinateurs et lquipement
command par ordinateur tel que les robots.
D Veiller ce que tout lquipement de la zone de soudage soit compatible au point de vue lectromagntique.
D Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : terre).
D Veiller souder une distance de 100 mtres de tout quipement
lectronique sensible.
D Veiller ce que le poste de soudage soit pos et mis la terre conformment au prsent manuel.
D En cas dinterfrences aprs excution des directives 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.
LES CHAMPS MAGNTIQUES peuvent

affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez distance.
D Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mdecin avant de sapprocher des oprations de soudage larc, de gougeage ou de soudage par points.
OM-359 Page 7
1-4. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(tlphone : (305) 4439353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800)

4636727 ou Toronto : (416) 7474044, site Web : www.csainternational.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (tlphone : (305) 4439353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,

norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West
42nd Street, New York, NY 100368002 (tlphone : (212) 6424900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection

Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (tlphone : (617) 7703000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tlphone : (617) 7703000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P1,

de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 222024102 (tlphone : (703) 4120900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de lU.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312)
3532220, site Web : www.osha.gov).
1-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et les effets des champs magntiques basse frquence sur lorganisme
En parcourant les cbles de soudage, le courant cre des champs lectromagntiques. Les effets potentiels de tels champs restent
proccupants. Cependant, aprs avoir examin plus de 500 tudes qui
ont t faites pendant une priode de recherche de 17 ans, un comit
de spcialistes du National Research Council a conclu : Laccumulation de preuves na pas dmontr que lexposition aux champs
magntiques et aux champs lectriques haute frquence constitue un
risque pour la sant humaine . Toutefois, les tudes et lexamen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de rduire lexposition aux champs
lectromagntiques pendant le soudage ou le coupage.
OM-359 Page 8
Afin de rduire les champs lectromagntiques en milieu de travail, respecter les consignes suivantes :
1. Garder les cbles ensemble en les torsadant ou en les fixant avec du
ruban adhsif.
2. Mettre tous les cbles du ct oppos loprateur.
3. Ne pas senrouler les cbles autour du corps.
4. Garder le poste de soudage et les cbles le plus loin possible de soi.
5. Placer la pince de masse le plus prs possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur mdecin. Si ce dernier les dclare aptes, il leur est recommand de respecter les consignes ci-dessus.
SECTION 2 DEFINITIONS
2-1. 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
3.1
1.2
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
2.2
2.3
3.2
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
3.3
197 310-A
OM-359 Page 9
2-2. Torch/Cable Holder Label

1
1
2
3
Warning! Watch Out! There

are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Do not operate unit or reach
inside when torch/cable
holder is removed.
Do not exceed 25 lb (12.4 kg)
maximum load on gun/cable
holder or holder may break.
2-3. Weld Cable Connection Label

1
1
2
3
OM-359 Page 10
Warning! Watch Out! There

are possible hazards as
shown by the symbols.
Electric shock from welding
electrode or wiring can kill.
Welding sparks or arcing from
unused electrode can cause
explosion or fire.
Do not connect more than one
electrode cable to any single
weld output terminal.
Disconnect cables for process
not in use. Have only one
welding circuit (process)
connected at any given time
never two.
2-4. Symbols And Definitions
NOTE
A
V
Some symbols are found only on CE products.
Amperes
PanelLocal
Gas Tungsten Arc

Welding (GTAW)
Shielded Metal Arc

Welding (SMAW)
Volts
Do Not Switch
While Welding
Arc Force (DIG)
Background Amps
Output
Circuit Breaker
Remote
Temperature
Protective Earth
(Ground)
Alternating Current
High Frequency Start
Input
Postflow Timer
Preflow Timer
High Frequency Continuous
Gas (Supply)
Gas Input
Gas Output
Increase/Decrease
Of Quantity
On
Off
Percent
Direct Current
Balance Control
Maximum Cleaning
Maximum
Penetration
Electrode Positive
Electrode
Negative
Final Slope
Meter
Single-Phase
Line Connection
U0
Rated No Load
Voltage (Average)
U1
Primary Voltage
U2
Conventional Load
Voltage
I1
Primary Current
I2
Rated Welding
Current
Duty Cycle
IP
Degree Of
Protection
I1eff
Maximum Effective
Supply Current
I1max
Rated Maximum
Supply Current
Hz
Single-Phase
Combined AC/DC
Power Source
Hertz
Electrode
Work
Thickness Gauge
Spark Gap
Seconds
Final Amperage
Initial Time
Initial Amperage
Pulse Percent On
Time
Spot Time
Lift-Arct
Trigger Hold
Pulser On-Off
Pulse Frequency
4T
4 Step Trigger Operation Sequence
OM-359 Page 11
SECTION 3 INSTALLATION
3-1. Selecting A Location
Y Falling
Injury.
S
Movement
S
OR
2
1
2
Unit
Can
Cause
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.
Lifting Eye
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
Locate unit near correct input power supply.

Y Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
Section 20.
Y Be careful when placing or
moving unit over uneven
surfaces.
Location And Airflow
3
18 in (460 mm)
18 in (460 mm)
Ref. ST-117 264-C / ST-802 455-C
OM-359 Page 12
3-2. Dimensions And Weights

Dimensions
A
D
C
Height
33-1/4 in (845 mm)
Width
22-1/2 in (572 mm)
Length
25 in (635 mm)
25 in (635 mm)
1-25/64 in (35 mm)
1-5/8 in (41 mm)
20-5/8 in (524 mm)
19-15/16 (506 mm)
22-1/4 (565 mm)
1-5/32 in (30 mm)
1/2 in (13 mm) Dia
Front
H 8 Holes
Ref. 207 559
Weight
389 lbs (176 kg)
3-3. Specifications
Amperes Input at AC Balanced Rated
Load Output, 60 Hz, Single-Phase
Rated
Welding Output
PFC**
200V
230V
NEMA Class I (40)

200 Amperes, 28
Volts AC, 60% Duty
Cycle
No
PFC
88
77
*3.3
*2.8
NEMA Class I (40)

200 Amperes, 28
Volts AC, 60% Duty
Cycle
With
PFC
60
52
*55.3
*49.5
NEMA Class II (40)

250 Amperes, 30
Volts AC, 40% Duty
Cycle
No
PFC
110
96
*3.3
*2.8
NEMA Class II (40)

250 Amperes, 30
Volts AC, 40% Duty
Cycle
With
PFC
82
71
*55.3
*49.5
460V
575V
KVA
38
31
17.6
8.6
*1.5
*1.1
*.59
*.29
26
21
12.06
8.11
*24.5
*19.6
*11.2
*.39
48
38
21.98
11.76
*1.5
*1.1
*.59
*.29
35
28
16.32
11.81
*24.5
*19.6
*11.2
*1.93
KW
Amperage
Range
Max
OCV
5 310A
80V
5 310A
80V
5 310A
80V
5 310A
80V
*While idling
**Power Factor Correction
OM-359 Page 13
3-5.
Specifications(continued)
Load Output, 50/60 Hz, Single-Phase
Rated
Welding Output
PFC**
220V
400V
NEMA Class I (40)

200 Amperes, 28
Volts AC, 60% Duty
Cycle
No
PFC
82
45
*3.0
*1.6
NEMA Class I (40)

200 Amperes, 28
Volts AC, 60% Duty
Cycle
With
PFC
61
34
*45.9
*25.1
NEMA Class II (40)

250 Amperes, 30
Volts AC, 40% Duty
Cycle
No
PFC
100
55
*3.0
*1.6
NEMA Class II (40)

250 Amperes, 30
Volts AC, 40% Duty
Cycle
With
PFC
81
44
*45.9
*25.1
440V
520V
KVA
41
35
17.6
8.6
*1.4
*1.2
*.59
*.29
31
26
12.06
8.11
*22.8
*23.2
*11.2
*.39
50
42
21.98
11.76
*1.4
*1.2
*.59
*.29
40
34
16.32
11.81
*22.8
*23.2
*11.2
*1.93
KW
Amperage
Range
Max
OCV
5 310A
80V
5 310A
80V
5 310A
80V
5 310A
80V
Amperage
Range
Max
OCV
5 310A
80V
5 310A
80V
5 310A
80V
5 310A
80V
*While idling

Load Output, 50 Hz, Single-Phase
Rated
Welding Output
PFC**
200V
230V
460V
575V
KVA
KW
NEMA Class I (40)

175 Amperes, 27
Volts AC, 60% Duty
Cycle
No
PFC
80
69
35
28
15.9
7.4
*3.3
*2.8
*1.5
*1.1
*.59
*.29
NEMA Class I (40)

175 Amperes, 27
Volts AC, 60% Duty
Cycle
With
PFC
52
45
22
18
10.3
7.3
*55.3
*49.5
*24.5
*19.6
*11.2
*.39
NEMA Class II (40)

225 Amperes, 29
Volts AC, 40% Duty
Cycle
No
PFC
101
88
44
35
20.2
10.2
*3.3
*2.8
*1.5
*1.1
*.59
*.29
NEMA Class II (40)

225 Amperes, 29
Volts AC, 40% Duty
Cycle
With
PFC
74
64
32
26
14.7
10.1
*55.3
*49.5
*24.5
*19.6
*11.2
*1.93
*While idling
OM-359 Page 14
3-4. Duty Cycle And Overheating

Duty Cycle is the percentage of 10
minutes that the unit can weld at
rated load without overheating.
If unit overheats, output stops, front
panel voltmeter/ammeter displays
a HLP3 or HLP5 message (see
Section 5-4), and cooling fans run.
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void warranty.
40% Duty Cycle At 250 Amperes
4 Minutes Welding
60% Duty Cycle At 200 Amperes
6 Minutes Welding
6 Minutes Resting
4 Minutes Resting
Overheating
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / SB-116 198
OM-359 Page 15
3-5. Volt-Ampere Curves
Non Ce Models
The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
194 385-A / 194 384-A
Ce Models
205 631 / 205 632
OM-359 Page 16
3-6. Weld Output Terminals And Selecting Cable Sizes

Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 60%
Duty
Cycle
60 100%
Duty
Cycle
100
1/0
1/0
150
1/0
2/0
3/0
3/0
200
1/0
2/0
3/0
4/0
4/0
250
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
Y Do not use worn, damaged, undersized, or

poorly spliced cables.
Work
Electrode
Ref. ST-801 972-C
10 100% Duty Cycle
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
*Select weld cable size for pulsing application at peak amperage value..
S-0007-D
3-7. Remote 14 Receptacle Information

Socket*

connecting to receptacle.
Contactor control 24 volts dc.
Contact closure to A completes 24 volts dc

contactor control circuit and enables output.
Output to remote control; 0 to +10 volts dc output

to remote control.
REMOTE
OUTPUT
CONTROL
Remote control/feedback circuit common.
0 to +10 volts dc input command signal from

remote control.
24 VOLTS DC
A
B
J
I
H
C L N
D M
G
E F
Ref. ST-801 972-C
Socket Information
OUTPUT
CONTACTOR
A/V
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
Voltage feedback; +1 volt dc per 10 volts output.
GND
Chassis common.
*The remaining sockets are not used.

OM-359 Page 17
3-8. Automation 10-Pin Connection (Optional)

Socket
Start/Stop
Gas
Output disabled
Chassis ground
Final slope collector
Final slope emitter
Pulse lockout collector
Pulse lockout emitter
Valid arc collector
Valid arc emitter
Socket Information For 10-Pin Receptacle RC3
I
A

connecting to receptacle
Ref. ST-801 972-C
Definitions Of Inputs And Outputs

Inputs
A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100ms, but
less than 3/4 seconds) starts and stops weld output.
B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initiation.
C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to
time out, and HELP 13 will be displayed on the meters.
Outputs
Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30
VDC.
Final Slope - output is on when in Final Slope.
Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10
Hz.
Arc On - output is on when the contactor is on and there is less than 50 load volts.
OM-359 Page 18
3-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle

Y Turn Off power before connecting to receptacle.
1
4
Gas Valve In Fitting
Located on rear of unit.

2
3
Gas Valve Out Fitting
Fittings have 5/8-18 right-hand

threads.
3
Cylinder Valve
Open valve slightly so gas flow

blows dirt from valve. Close valve.
Tools Needed:
5/8, 3/4, 1-1/8 in
Regulator/Flow Gauge
Connect regulator/flow gauge to

gas cylinder.
Connect customer supplied gas
hose between regulator/flow gauge
and gas in fitting.
Flow Adjust
Typical flow rate is 20 cfh (cubic feet

per hour).
115 V 15 Amp AC Receptacle
Receptacle is protected from overload by circuit breaker CB1 (see

Section 5-2).
Front View
Rear View
Ref. ST-801 972-C / Ref. ST-801 973 / Ref. ST-157 858
3-10. TIG Connections

Y Turn Off power before making connections.
1
Gas In Connection
Connect gas hose from gas supply

to gas in fitting.
2
Switch is shown in DCEN (direct

current electrode negative) position
for TIG HF Impulse DCEN welding.
For front panel control dispay, see
Section 3-11. For TIG AC welding,
place switch in AC position (see
Section 4-2). For TIG AC front panel control dispay, see Section 3-12.
11/16, (21 mm), 3/4 in
Remote 14 Receptacle
Connect desired remote control to

Remote 14 receptacle.
5
Tools Needed:
Work Weld Output Terminal
Connect work lead to work weld

output terminal.
1
Output Selector Switch (See

Section 4-2)
Electrode Weld Output

Terminal
Connect TIG torch to electrode

weld outout terminal.
6
Gas Out Connection
Connect torch gas hose to gas out

fitting.
802 734-C
OM-359 Page 19
3-11. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)
1
Front Panel
Correct front panel display for basic

TIG HF Impulse DCEN welding.
. For all front panel switch pad
controls: press switch pad to

turn on light and enable function.
NOTE: Green on nameplate indicates a TIG function (see Section

4-1 for description of controls).
OM-359 Page 20
CE Models
OM-359 Page 21
3-12. Front Panel Display For TIG AC

1
Front Panel

TIG AC welding.

NOTE: Green on nameplate indicates a TIG function (see Section

4-1 for description of controls).
OM-359 Page 22
CE Models
OM-359 Page 23
Notes
OM-359 Page 24
3-13. Stick Connections

Y Turn Off power before making connections.
1
Work Weld Output Terminal
Connect work lead to work weld

output terminal.
2
Electrode Weld Output

Terminal
Connect electrode holder to electrode weld outout terminal.

3
Remote 14 Receptacle
If desired, connect remote control

to Remote 14 receptacle.
4
1
Output Selector Switch (See

Section 4-2)
Switch is shown in DCEP (direct

current electrode positive) position
for Stick DCEP welding. For front
panel control dispay, see Section
3-14. For Stick AC welding, place
switch in AC position (see Section
4-2). For Stick AC front panel control dispay, see Section 3-15.
Tools Needed:
11/16, (21 mm), 3/4 in
802 733-C
OM-359 Page 25
3-14. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1
Front Panel

Stick DCEP welding.

NOTE: Gray on nameplate indicates

a Stick function (see Section 4-1 for
description of controls).
OM-359 Page 26
CE Models
OM-359 Page 27
3-15. Front Panel Display For Stick AC

1
Front Panel

Stick AC welding.

NOTE: Gray on nameplate indicates

a Stick function (see Section 4-1 for
description of controls).
OM-359 Page 28
CE Models
OM-359 Page 29
3-16. Electrical Service Guide
NOTE
All values in both tables were calculated at 60% duty cycle.

50/60 Hertz Models
Without Power Factor Correction
Input Voltage
200
220
230
400
440
460
520
575
Input Amperes At Rated Output
88
82
77
45
41
38
35
31
Time-Delay Fuse 2
125
125
125
70
60
60
50
45
Normal Operating (Fast) Fuse 3
125
125
125
70
60
60
50
45
10
10
10
167
(51)
137
(42)
153
(47)
305
(93)
369
(112)
281
(86)
352
(107)
439
(134)
10
10
10
10
Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In AWG/Kcmil

Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.
2 Time-Delay fuses are UL class RK5 .
3 Normal Operating (fast) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
50/60 Hertz Models
With Power Factor Correction
Input Voltage
200
220
230
400
440
460
520
575
Input Amperes At Rated Output
60
61
52
34
31
26
26
21
Time-Delay Fuse 2
90
90
80
50
45
40
40
30
Normal Operating (Fast) Fuse 3
90
90
80
50
45
40
40
30
10
10
10
10
12
87 (26)
102
(31)
115
(35)
226
(69)
274
(84)
308
(94)
383
(117)
295
(90)
10
10
10
10
12
Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In AWG/Kcmil

Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.
2 Time-Delay fuses are UL class RK5 .
3 Normal Operating (fast) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
OM-359 Page 30
3-17. Placing Jumper Links

Y Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Check input voltage available at
site.
1
200 VOLTS
230 VOLTS
460 VOLTS
2
L
S-083 566-C
230 VOLTS
L
460 VOLTS
Jumper Link Label
Check label only one is on unit.

Jumper Links
Move jumper links to match input

voltage.
Close and secure access door, or
go on to Section 3-18.
575 VOLTS
L
L
S-010 587-B
Tools Needed:
3/8 in
Ref. ST-801 973-B
OM-359 Page 31
3-18. Connecting Input Power

1
GND/PE
Earth Ground
1
9
3
8
When making connections in

the line disconnect device,
connect the Green Or
Green/Yellow conductor first.
Install conductors into

a deenergized line
disconnect device.
6
Make connections to machine
first and supply last.
Connect Green Or
Green/Yellow GND/PE
Conductor First
Tools Needed:
3/8 in
5
3
Ref. ST-801 973-B
Y Disconnect and lockout/tagout input power before connecting input

conductors from unit.
Y Have only qualified persons make
this installation.
See rating label on unit and check input
voltage available at site.
1
2
3
Line Disconnect Device

Input Conductors
Grounding Conductor
Select size and length using Section 3-16.

Conductors must comply with national,
state, and local electrical codes. If applicable, use lugs of proper amperage capacity
and correct hole size.
OM-359 Page 32
4 Strain Relief
Route conductors through strain relief.
5 Machine Grounding Terminal
6 Line Terminals
Y Make input power connections to
the welding power source before
making connections into a deenergized line disconnect device.
Connect green or green/yellow grounding
conductor to machine grounding terminal
first. Then connect input conductors to line
terminals.
Close access door.
7 Disconnect Device (Supply)
Grounding Terminal
8 Disconnect Device Line Terminals
Y In the deenergized line disconnect

device, connect green or green/yellow grounding conductor to supply
grounding terminal first, never to a
line terminal. Be sure grounding
conductor goes to an earth ground.
Connect input conductors to line terminals.
9
Overcurrent Protection
Select type and size using Section 3-16

(fused disconnect switch shown).
Close door on line disconnect device.
SECTION 4 OPERATION
4-1. Controls
A. For 200/230/460 Volts And Non CE Units
12
1
13
11
10
. Top row of lights in upper left corner are On

for SMAW. Bottom row are On for GTAW.
Green on nameplate indicates a TIG function,

Gray indicates a Stick function.
1
Process Control
See Section 4-3.

2
Amperage Control
See Section 4-4.

3
Output Control
Voltmeter
See Section 4-10

6
Ammeter
See Section 4-10

7
Amperage Adjustment
Control
10 Postflow Time Control

See Section 4-14.
11 Balance/DIG Control
See Section 4-11.
See Section 4-12.
12 Pulser Controls (Optional)
Output Selector Switch
See Section 4-5.
See Section 4-2.
See Section 4-15.
13 Sequence Controls (Optional)
Start Mode Control
See Section 4-9.
Power Switch
Use switch to turn unit Off and On.
See Section 4-16.
204 776 / Ref. ST-801 972
OM-359 Page 33
B. For CE Units
12
1
13
11
10
. Top row of lights in upper left corner are On

for SMAW. Bottom row are On for GTAW.
Green on nameplate indicates a TIG function,

Gray indicates a Stick function.
1
Process Control
See Section 4-3.

2
Amperage Control
See Section 4-4.

3
Output Control
Voltmeter
See Section 4-10

6
Ammeter
See Section 4-10

7
Amperage Adjustment
Control
10 Postflow Time Control

See Section 4-14.
11 Balance/DIG Control
See Section 4-11.
See Section 4-12.
12 Pulser Controls (Optional)
See Section 4-5.
See Section 4-2.
See Section 4-15.
13 Sequence Controls (Optional)
Start Mode Control
See Section 4-9.
Power Switch
Use switch to turn unit Off and On.
See Section 4-16.

208 242 / Ref. ST-801 972-C
OM-359 Page 34
4-2. Output Selector Switch

1
(CE Nameplate)
Y Do not use AC output in

damp areas, if movement is
confined, or if there is danger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
Y Do not change position of
switch while welding or
while under load.
Use switch to select (DCEN) Direct

Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output.
NOTE: Changing position of Output Selector switch may also
change Process control, Current
control, Output control, and Start
Mode control settings to properly
function with latest Output Selector
switch setting.
4-3. Process Control

(CE Nameplate)
Process Control
Use control to select Shielded Metal Arc Welding (SMAW) or Gas

Tungsten Arc Welding (GTAW) process.
For SMAW, press button to toggle
LED to Stick position.
For GTAW, press button to toggle
LED to TIG position.
1
NOTE: Lit LED indicates selected

mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
Ref. ST-196 616 / Ref. ST-196 764
4-4. Amperage Control

(CE Nameplate)
Amperage Control
Use control to select front panel or

remote amperage control.
For front panel amperage control,
press button to toggle LED to Panel
position.
For remote amperage control,
press button to toggle LED to Remote position (see Section 3-7).
NOTE: Lit LED indicates selected
mode.
1
When Output Selector switch position changes, LED may change

position, based upon last selection.
OM-359 Page 35
4-5. Output Control

Remote (Standard)Torch Trigger Operation
(CE Nameplate)
Current (A)
Remote (Standard)Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold

Foot Or Finger
Remote Control
Output Control
Y Weld output terminals are energized when power is On, and Output On LED is lit.
Use control to select front panel, trigger
hold, or remote output control.
NOTE: Lit LED indicates selected mode.
For weld output, press button to toggle LED
to On position.
OM-359 Page 36
Release For
Maintained Switch
Remote Trigger (Standard) Operation
For remote output control, press button to

toggle LED to Remote position (see Section 3-7).
Torch trigger operation is as shown.
NOTE: Initial weld amperage and final amperage is controlled by the remote device,
not by the welding power source.
Release Foot Or
Finger Remote
Control
NOTE: If On/Off only type trigger is used,

it must be a maintained switch. All functions become active.
Application: Use Remote Trigger when
the operator desires to use a foot pedal or
finger amperage control.
When Output Selector switch (see Section
4-2) position changes, Output control LED
will always switch to Remote.
When Output On is selected, HF and gas
control are disabled.
Trigger Hold (2T)
(CE Nameplate)
Current (A)
2T Torch Trigger Operation

Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release Trigger

In Less Than 3/4 Sec.
Push & Release Trigger

In Less Than 3/4 Sec.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous
page).
If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-4).
Trigger Hold
For trigger hold operation, press button to

toggle LED to Trigger Hold position.
NOTE: When a foot or finger remote control is connected to the welding power
source, only trigger input is functional.
NOTE: Amperage is controlled by the
welding power source.

Application: Use Trigger Hold (2T)
when long extended welds are made.
Trigger Hold (2T) can help to reduce operator fatigue.
OM-359 Page 37
4-6. 4T, 4T Momentary And Mini Logoic Trigger Operation (RequiresOptional Sequence
Controls)
4T Torch Trigger Operation
If unit is equipped with optional Sequence
Controls (see Section 4-16), 4T trigger
method is available.
lows the operator to toggle between weld

current and final current without breaking
the arc.
4T torch trigger operation is as shown.
NOTE: When a remote switch is connected

to the welding power source, only trigger input is functional. Amperage is controlled by
the welding power source.
While in 4T mode, there is a feature available during the main weld sequence that al-
Application:
Use 4T trigger method when the functions
of a remote current control are desired, but
only a remote on/off control is available.
Select 4T trigger method according to Section 4-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold

Trigger
Release
Trigger
Push & Release

Trigger In Less
Than 3/4 Sec.
Push & Release

Trigger In Less
Than 3/4 Sec.
Push & Hold

Trigger
Release
Trigger
4T Momentary Torch Trigger Operation

Controls (see Section 4-16), 4T Momentary trigger method is available.
4T Momentary torch trigger operation is as
shown.
While in 4T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break
the arc and go to postflow.

Application:
Use 4T Momentary trigger method when
the functions of a remote current control are
desired, but only a remote on/off control is
available.
Select 4T Momentary trigger method according to Section 4-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release

Trigger
OM-359 Page 38
Push & Release

Trigger
Push & Release

Trigger
Push & Release

Trigger
Mini Logic Operation

Controls (see Section 4-16), Mini Logic operation is available.
During Mini Logic welding operation, the
weld amperage can be manually changed
from the initial amps level to the main weld

amps level by pressing and releasing the
torch trigger in less than 3/4 seconds.

Application: This ability to change amperage levels without either initial slope or final
slope, gives the operator the opportunity to
adjust filler metal without breaking the arc.
Select Mini Logic according to Section 4-7.
Weld Amps
Final Slope
Initial Amps
Initial Amps
Final Slope
Rate
Preflow
Push & Hold

Trigger
Push & Hold

Trigger For More
Than 3/4 Sec.
Release Trigger
Push & Release

Trigger In Less
Than 3/4 Sec.
Postflow
Push & Release

Trigger In Less
Than 3/4 Sec.
Push & Hold

Trigger For More
Than 3/4 Sec.
Push & Release

Trigger In Less
Than 3/4 Sec.
OM-359 Page 39
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control

1
2
Output Control
Power Switch
To reconfigure Trigger Hold, turn Off

power, push and hold Output control
button and turn On power switch.
Hold button for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters
display [SEL] [H2].
Front Panel
Press Output control button to

change functions. Active function will
be displayed on amperage (bottom)
meter.
3
Meter Displays
Meter displays for the different functions will be as shown.

Press torch trigger or turn power Off
to save setting.
SEL
Proceed to Section 4-6 for 4T Operation.

Proceed to Section 4-6 for Mini Logic
operation.
H-2
Proceed to Section 4-6 for 4T Momentary operation.

NOTE: These features are only
available when optional Sequencer
is installed.
SEL
H4E
= 4T Momentary
(See Section 4-6)
SEL
SEL
= Mini Logic (See Section 4-6)
= 4T (See Section 4-6)
H-4
H4L
OM-359 Page 40
(CE Nameplate)
Front Panel
SEL
H-2
SEL
H4E
= 4T Momentary
(See Section 4-6)
SEL
SEL
= Mini Logic (See Section 4-6)
= 4T (See Section 4-6)
H-4
H4L
OM-359 Page 41
4-8. Selecting TIG Starting Characteristics

1
SEL
-2-
2
3
Use this function to select desired TIG starting characteristics.

1 Start Mode
2 Power Switch
3 Output Selector Switch
4 Meters
To select or change TIG starting characteristics, proceed as follows: turn Off power.
Place Output Selector switch in desired position (each position, DCEN, AC, or DCEP has
three applicable start characteristics op-
OM-359 Page 42
tions). Push and hold Start Mode button and

turn On power. Hold button for approximately
7 seconds (or until software version number_
_ _ _ _ _-_ clears meters).
The TIG LED and all four Start LEDs will light,
and the meters will display [SEL] [-2-].
Press Start Mode button again to step
through the three start characteristics
choices. Amperage (bottom) meter displays
active choice 1= light start, 2=medium/normal
start, 3=high/hot start.
Press torch trigger or turn Off power to save

setting.
Application:
Select 1 (light/soft start) when welding at low
amperages on thin gauge material.
Select 2 (medium/normal start) factory default setting used for most welding applications.
Select 3 (high/hot start) when welding at
high amperages on thick materials with a
large diameter tungsten.
(CE Nameplate)
SEL
-2-
OM-359 Page 43
4-9. Start Mode

(CE Nameplate)
Lift-Arct Start Method
Touch
12
Seconds
Do NOT Strike Like A Match!
Start Mode
For SMAW welding, press button to toggle

LED to Off position.
For GTAW welding, use control to select
Off for no HF, Lift-Arct, HF for arc starting
only, or continuous HF.
Application:
When Off is selected, use the scratch
method to start an arc for both the SMAW
and GTAW processes.
When Lift-Arc is selected, start arc as
follows:
2
TIG Electrode
Workpiece
Touch tungsten electrode to workpiece at

weld start point, enable output with torch
trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2 sec-
OM-359 Page 44
onds, and slowly lift electrode. An arc will

form when electrode is lifted.
turns off when arc is started, and turns on

whenever arc is broken to help restart arc.
Shielding gas begins to flow when electrode touches work piece.
Application:
Normal open-circuit voltage is not present

before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece.
The solid state output contactor does not
energize until after electrode is touching
workpiece. This allows electrode to touch
workpiece without overheating, sticking,
or getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.
HF Start is used when the DCEN GTAW

process is required.
When HF Continuous is selected, start
arc as follows:
High frequency turns on when output is
energized and remains on for duration of
weld.
Application:
HF Continuous is used when the AC
GTAW process is required.
NOTE: Lit LED indicates selected mode.
When HF Start is selected, start arc as

follows:
When Output Selector switch position

changes, LED may change position,
based upon last selection.
High frequency turns on to help start arc

when output is enabled. High frequency
NOTE: Some start methods may not be

available for all processes.
4-10. Meters
1
Voltmeter
Voltmeter displays average voltage

(to the nearest 0.1 V) at the weld
output terminals.
Ammeter
Use meter to preset amperage. Meter displays average weld amperage output of unit to nearest ampere when welding.
NOTE: Meters are self-calibrating.
No adjustment available.
2
4-11. Amperage Adjustment Control

1
(CE Nameplate)
1
Amperage Adjustment Control
Use control to adjust amperage,

and preset amperage on ammeter
(see Section 4-10). This control
may be adjusted while welding.
For remote amperage control,
front panel control setting is the
maximum amperage available. For
example: If front panel control is set
to 200 A, the range of the remote
amperage control is 5 to 200 A.
For pulse welding, use Amperage
Adjust control to select from 5300
amps of peak amperage (see Section 4-15).
For spot welding, use Amperage
Adjust control to select from 5300
amps of peak amperage (see Section 4-19).
OM-359 Page 45
4-12. Balance/DIG Control

1
(CE Nameplate)
Balance/DIG Control
Balance Control (AC GTAW):
Control changes the AC output

square wave. Rotating the control
towards 10 provides deeper penetration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
Application:
Balance Control Examples

Setting
Balanced
3
Output Waveforms
50% Electrode
Positive
50% Electrode
Negative
More Penetration
10
More Cleaning
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
Arc
When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only
a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
along the weld toes is required.
Set control to 7 and adjust as necessary. Joint configuration, set-up,
process variables, and oxide thickness may affect setting.
NOTE: Arc rectification can occur
when welding above 200 amps
and/or while welding with helium
gas. If this condition occurs, increasing the Balance control towards maximum penetration, may
help to restabilize the arc.
DIG Control (AC And DC SMAW):
When set at 0, short-circuit amperage at low arc voltage is the same
as normal welding amperage.
When setting is increased, shortcircuit amperage at low arc voltage
increases.
Application:
Control helps arc starting or making
vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking
while welding.
Ref. S-0795-A
OM-359 Page 46
Notes
OM-359 Page 47
4-13. Preflow Time Control

1
00.2
SEL
Use control to set length of time (0.2, 0.4, 0.6,

0.8, 1.0, 2.0 or 4.0 seconds) gas flows before
welding starts.
1 Process Control
2 Power Switch
3 Meters
To change preflow time, proceed as follows:
OM-359 Page 48
Turn power off. Push and hold Process Control button and turn On power. Hold button for
approximately 7 seconds (or until software
version number_ _ _ _ _ _-_ clears meters).
time, press and release Process Control button until desired time is displayed on meters.
The TIG LED will light and the meters will display [o.2] [SEL]. The factory preflow default
setting is 0.2 seconds. To change preflow
Preflow is used to purge the immediate weld

area of atmosphere. Preflow also aids in consistent arc starting.
Application:
(CE Nameplate)
00.2
SEL
OM-359 Page 49
4-14. Postflow Time Control

1
(CE Nameplate)
Postflow Time Control
Use control to set length of time

(050 seconds) gas flows after
welding stops. It is important to set
enough time to allow gas to flow until after the tungsten and weld
puddle has cooled down.
Application:
Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or
weld are dark in appearance
(approximately 1 second per 10
ampere of welding current).
OM-359 Page 50
4-15. Pulse Controls (Optional)

1
3
On/Off Control
Use control to turn pulse function

On and Off.
2
Background Amps
Use Background Amps control to

set the low pulse of the weld amperage, which cools the weld
puddle and affects overall heat input. Background Amps is set as a
percentage of peak amperage.
3
(CE Nameplate)
3
Pulse Frequency
Ranges from 0.2510.0 pps

(pulses per second). Control is
used to determine appearance of
weld bead.
4
Peak Time
A range of 595% of each pulse

cycle can be spent at the peak
amperage level.
Percent (%) Peak

Time Control Setting
Pulsed Output Waveforms

PPS
(50%)
Bkg Amp
Balanced
Peak Amp
More Time
At Peak
Amperage
More Time At
Background
Amperage
(80%)
(20%)
Peak amperage (5310 amps), is

set with the Amperage Adjustment control (see Section 4-1).
Peak amperage is the highest
welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak
amperage.
5
Pulsed Output Waveforms
Example shows affect changing

the Peak Time control has on the
pulsed output waveform.
Application:
Pulsing refers to the alternating
raising and lowering of the weld
output at a specific rate. The
raised portions of the weld output
are controlled in width, height,
and frequency, forming pulses of
weld output. These pulses and
the lower amperage level between them (called the background amperage) alternately
heat and cool the molten weld
puddle. The combined effect
gives the operator better control
of penetration, bead width,
crowning, undercutting, and heat
input. Controls can be adjusted
while welding.
Pulsing can also be used for filler
material addition technique
training.
NOTE: Function is enabled,
when LED is lit.
OM-359 Page 51
4-16. Sequence Controls (Optional)

1
Initial Time Control
See Section 4-17.

2
5
1
Initial Amperage Control
See Section 4-17.

3
Final Slope Control
See Section 4-18.

4
Final Amperage Control
See Section 4-18.

5
Spot Time Control
See Section 4-19.

4
(CE Nameplate)
5
1
Ref. ST-196 616 / Ref. ST-196 764
OM-359 Page 52
4-17. Initial Time Control And Initial Amperage Control

1
(CE Nameplate)
Initial Time Control
Indicator light is on when Initial

Time control function is active.
NOTE: Initial Sequence control

function is inactive when Spot Time
function is active.
Use control to select 015 seconds
of start time.
2
Initial Amperage Control
Indicator Light is on when Initial Sequence control function is active.

NOTE: Initial Amperage control
function is inactive when Spot Time
function is active.
Use control to select a starting amperage (5310 amps) that is different from the weld amperage. Note:
Initial Amperage can be used with
or without a remote control (Initial
Amperage and Initial Time control
settings will override a remote control device).
Application:
Initial Amperage can be used while
GTAW welding to assist in preheating cold material prior to depositing
filler material, or to ensure a soft
start. Initial Amperage can also be
used for SMAW to ensure a more
consistent arc strike.
NOTE: Function is enabled, when
LED is lit.
OM-359 Page 53
4-18. Final Slope Control And Final Amperage Control

1
(CE Nameplate)
Note: Final Slope control function

is inactive when Spot Time function is active.
Final Slope Control
Indicator light is on when Final

Slope control function is active.
Use control to reduce amperage

over a set period of time (015
seconds) at the end of the weld
cycle when NOT using a remote
current control.
2
Final Amperage Control
Indicator light is on when Final

Amperage control function is active.
Note: Final Amperage control
function is inactive when Spot
Time function is active (see Section 4-19).
Final amperage is the amperage

to which weld amperage has
sloped down to (0100% of amperage set on Amperage Adjust
control).
Application:
Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator wants to eliminate the crater at
the end of the weld.
Note: This applies if the operator
is using an on/off only type control
to start and stop the welding process.
Note: Do not use this function
with a foot or finger amperage
control.
NOTE: Function is enabled, when
LED is lit.
4-19. Spot Time Control

1
Spot Time Control
Indicator light is on when Spot

Time function is active. When
Spot Time function is active, Initial Time, Initial Amperage, Final
Slope, and Final Amperage
functions are inactive (see Section 4-16).
Used with the (GTAW) TIG Spot

process, generally with a direct
current electrode negative
(DCEN) set-up.
Use control to select 015 seconds of spot time.
(CE Nameplate)
1
Use Amperage Adjust control

(see Section 4-11) to set amperage.
Application:
TIG spot welding is used for joining thinner materials that are in
close contact with the fusion
method. A good example would
be joining coil ends.
NOTE: Function is enabled,
when LED is lit.
OM-359 Page 54
4-20. Timer/Cycle Counter
1 2 3
1
4 5 6
(CE Nameplate)
1 2 3
4
4 5 6
1 Amperage Control
2 Output Control (Contactor)
To read timer/cycle counter, hold Amperage and Output (contactor) buttons while
turning on power.
Timer Display
The hours and minutes are displayed on

the volt and amp meters for the first five
seconds, and are read as 1, 234 hours
and 56 minutes.
Cycle Display
The cycles are displayed on the volt and

amp meters for the next five seconds,
and are read as 123, 456 cycles.
OM-359 Page 55
4-21. Resetting Unit To Factory Default Settings (All Models)
1
2
3
4
Process Control
Amperage Control
Output Control
Start Control
OM-359 Page 56
Power Switch
To reset all welding power source functions

to original factory settings, turn power off.
Push and hold the Process, Amperage,
Output and Start controls and turn On power. Hold switch pads for approximately 7
seconds (or until software version number
_ _ _ _ _ _-_clears meters).
CE Models
OM-359 Page 57
SECTION 5 MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Weld
Cables
Replace
Unreadable
Labels
Replace
Cracked
Parts
Adjust Spark
Gaps
14-Pin Cord
Torch Cable
Gas Hose
6 Months
Blow Out Or Vacuum
Inside,
During Heavy Service,
Clean Monthly
OR
5-2. Circuit Breaker CB1

Y Turn off power before resetting breaker.
1
1
Circuit Breaker CB1
If CB1 opens, high frequency and

output to the 115 volts ac duplex receptacle stop. Press button to reset
breaker.
Ref. ST-801 972-C
OM-359 Page 58
5-3. Adjusting Spark Gaps

Y Turn Off welding power
source and disconnect and
lockout/tagout input power
before adjusting spark gaps.
Open access door.
1
Tungsten End Of Point
Replace point if tungsten end disappears; do not clean or dress

tungsten.
2
2
Spark Gap
Normal spark gap is 0.012 in (0.305

mm).
If adjustment is needed, proceed as
follows:
3
Adjustment Screws
Loosen screws. Place gauge of

proper thickness in spark gap.
3
Pressure Point
Apply slight pressure at point until

gauge is held firmly in gap. Tighten
screws. Adjust other gap.
Reinstall access door.
Tools Needed:
0.012 in (0.305 mm)
5/32 in
Ref. ST-801 972-C / Ref. S-0043
OM-359 Page 59
5-4. Voltmeter/Ammeter Help Displays

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

0 Help 0 Display
Indicates a short in the thermal protection circuitry located on the transformer of the unit.
If this display is shown, contact a Factory Authorized Service Agent.
1 Help1 Display
An SCR overcurrent condition has occurred.
Turn power off and back on to correct condition. If problem continues, contact a Factory
Authorized Service Agent.
2 Help 2 Display
Indicates a malfunction in the thermal
protection circuitry located on the transformer of the unit. If this display is shown, contact
a Factory Authorized Service Agent.
3 Help 3 Display
Indicates the transformer of the unit has
overheated. The unit has shut down to allow
the fan to cool it (see Section 3-4). Operation

will continue when the unit has cooled.
4
Help 4 Display
Indicates a malfunction in the thermal

protection circuitry located on the rectifier
assembly of the unit. If this display is shown,
contact a Factory Authorized Service Agent.
5
Help 5 Display
Indicates the rectifier assembly of the unit

has overheated. The unit has shut down to
allow the fan to cool it (see Section 3-4). Operation will continue when the unit has
cooled.
6
Help 6 Display
Help 9 Display
10 Help 10 Display
Indicates Remote Output control is activated. Release Remote Output control to
clear help message.
11 Help 11 Display
Indicates Output Selector switch is not in
correct position (see Section 4-2).
Indicates a non-allowable set-up on the front
panel.
Help 7 Display
13 Help 13 Display
Not used.
8
Indicates a short in the thermal protection circuitry located on the rectifier assembly of the
unit. If this display is shown, contact a Factory Authorized Service Agent.
12 Help 12 Display
Not used.
7
Not used.
AIC option, output enable signal broken

causing weld output to stop, but gas continues to flow.
Help 8 Display
HLP
HLP
HLP
HLP
HLP
--0
--1
--2
--3
--4
HLP
HLP
HLP
HLP
HLP
--5
--6
--7
--8
--9
10
11
12
13
HLP
HLP
HLP
HLP
-10
-11
-12
-13
OM-359 Page 60
5-5. Troubleshooting
NOTE: The remedies listed below are recommendations only. If these remedies do not fix
the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 5-4 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-18).
Check and replace line fuse(s), if necessary (see Section 3-18).
Check for proper input power connections (see Section 3-18).
Check for proper jumper link position (see Section 3-17).
No weld output; unit on.
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 4-1).
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check unit.
Unit provides only maximum or

minimum weld output.
Make sure Amperage control is in proper position (see Section 4-1).

Have Factory Authorized Service Agent check unit.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-6).
Clean and tighten all weld connections.
Check position of Output Selector control (see Section Figure 4-1).
If using remote control, check position of Amperage Adjustment control (see Section 4-1).
No control of weld output.
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 4-1).
Make sure Amperage control is in proper position (see Section 4-1).
No output from duplex receptacle RC2

and no high frequency.
Reset circuit breaker CB1 (see Section 5-2).
Lack of high frequency; difficulty in

starting GTAW arc.
Reset circuit breaker CB1 (see Section 5-2).

Select proper size tungsten.
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connections. Repair or replace.
Check spark gaps (see Section 5-3).
Wandering arc poor control of

direction of arc.
Reduce gas flow rate.

Select proper size tungsten.
Properly prepare tungsten.
Tungsten electrode oxidizing and not

remaining bright after conclusion of
weld.
Shield weld zone from drafts.

Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary.
Fan not operating.
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
OM-359 Page 61
SECTION 6 ELECTRICAL DIAGRAM
194 381-K
Figure 6-1. Circuit Diagram All Models

OM-359 Page 62
SECTION 7 HIGH FREQUENCY

7-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG helps arc jump air gap

between torch and workpiece and/
or stabilize the arc.
Work
TIG
high_freq 12/96 S-0693
7-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency

Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
Sources of Conduction of High

Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High

Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-359 Page 63
7-3. Correct Installation
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
High-Frequency Source (welding

power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
OM-359 Page 64
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections

using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Metal Building Requirements

9
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install

copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
Cover all windows and doorways with

grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
External Power or Telephone Lines
Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for

specifications.
11 Overhead Door Track

Ground the track.
SECTION 8 SELECTING AND PREPARING TUNGSTEN

ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2000
Y Whenever possible and practical, use DC weld output instead of AC weld output.
8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type - Polarity
Electrode Diameter
DC Argon Electrode
Negative/Straight Polarity
DC Argon Electrode Positive/Reverse Polarity
AC Argon
AC Argon
.010
Up to 25
Up to 20
Up to 15
.020
15-40
15-35
5-20
Balanced Wave
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium

(Red Band) Alloy Tungstens
.040
25-85
20-80
20-60
1/16
50-160
10-20
50-150
60-120
3/32
135-235
15-30
130-250
100-180
1/8
250-400
25-40
225-360
160-250
5/32
400-500
40-55
300-450
200-320
3/16
500-750
55-80
400-500
290-390
1/4
750-1000
80-125
600-800
340-525
.010
Up to 15
Up to 15
Up to 10
.020
5-20
5-20
10-20
.040
15-80
10-60
20-30
1/16
70-150
10-20
50-100
30-80
3/32
125-225
15-30
100-160
60-130
1/8
225-360
25-40
150-210
100-180
5/32
360-450
40-55
200-275
160-240
3/16
450-720
55-80
250-350
190-300
1/4
720-950
80-125
325-450
250-400
.010
Up to 20
Up to 15
.020
15-35
5-20
.040
20-80
20-60
1/16
50-150
60-120
3/32
130-250
100-180
1/8
225-360
160-250
5/32
300-450
200-320
3/16
400-550
290-390
1/4
600-800
340-525
Pure Tungsten
(Green Band)
Zirconium Alloyed Tungsten (Brown

Band)
Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
OM-359 Page 65
8-2. Preparing Tungsten Electrode For Welding

Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
1
1
2
Tungsten Electrode
Tapered End
Grind end of tungsten on fine grit,

hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
Stable Arc
Flat
Diameter of this flat determines

amperage capacity.
Grinding Wheel
Grinding wheel should be dedicated to grinding tungsten only.

4
Straight Ground
1
2
3
Arc Wander
Point
Grinding Wheel
Ideal Tungsten Preparation Stable Arc
2
3
Grinding wheel should be dedicated to grinding tungsten only.

4
Radial Ground
1
2
Tungsten Electrode
Balled End
Wrong Tungsten Preparation Wandering Arc
B. Preparing Tungsten For Conventional AC Welding
Y Understand and
follow
safety symbols at start of
Section 9-1 before preparing
tungsten.
1 1-1/2 Times
Electrode Diameter
OM-359 Page 66
Ball end of tungsten by applying AC

amperage recommended for a given electrode diameter (see Section
8-1). Let ball on end of the tungsten
take its own shape.
SECTION 9 GUIDELINES FOR TIG WELDING (GTAW)

9-1. Positioning The Torch
Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
. For additional information, see
your distributor for a handbook

on the Gas Tungsten Arc Welding (GTAW) process.
Workpiece
Make sure workpiece is clean

before welding.
4
Work Clamp
Place as close to the weld as

possible.
90
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten

according to Sections 8-1 and 8-2.
Guidelines:
1015
4
5
6
1025
The inside diameter of the gas cup

should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
The tungsten extension should be

no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
1/16 in
3/16 in
Bottom View Of Gas Cup
Ref. ST-161 892
OM-359 Page 67
9-2. Torch Movement During Welding

Tungsten Without Filler Rod
75
Welding direction
Form pool
Tilt torch
Move torch to front

of pool. Repeat process.
Tungsten With Filler Rod

75
Welding direction
Form pool
Tilt torch
Remove rod
15
Add filler metal
Move torch to front

of pool. Repeat process.
ST-162 002-B
OM-359 Page 68
9-3. Positioning Torch Tungsten For Various Weld Joints
90
Butt Weld And Stringer Bead
70
20
20
T Joint
75
10
15
20-40
Lap Joint
75
15
30
90
Corner Joint
75
15
ST-162 003 / S-0792
OM-359 Page 69
SECTION 10 STICK WELDING (SMAW) GUIDELINES
10-1. Stick Welding Procedure

Y Weld current starts when
electrode touches workpiece.
Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
1
5
2
3
4
2
Work Clamp
Electrode
A small diameter electrode requires

less current than a large one. Follow electrode manufacturers
instructions when setting weld amperage (see Section 10-2).
3
6
1
Workpiece
Make sure workpiece is clean before welding.
4
5
6
Insulated Electrode Holder

Electrode Holder Position
Arc Length
Arc length is the distance from the

electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
7
Slag
Use a chipping hammer and wire

brush to remove slag. Remove slag
and check weld bead before making another weld pass.
Tools Needed:
stick 12/96 ST-151 593
OM-359 Page 70
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
6010
ELECTRODE
6010
&
6011
100
50
DIAMETER
ELECTRODE
10-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH

HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)

EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
10-3. Striking an Arc Scratch Start Technique

1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece

like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to workpiece, use a quick twist to free it.
S-0049
10-4. Striking an Arc Tapping Technique

1
1
2
3
Electrode
Workpiece
Arc
Bring electrode straight down to

workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
3
S-0050
OM-359 Page 71
10-5. Positioning Electrode Holder

10-30
90
90
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10-30
45
45
End View of Work Angle
Side View of Electrode Angle

FILLET WELDS
S-0060
10-6. Poor Weld Bead Characteristics

1
2
3
4
5
Large Spatter Deposits

Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
S-0053-A
10-7. Good Weld Bead Characteristics

1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each

1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
No Overlap
Good Penetration into Base
Metal
S-0052-B
OM-359 Page 72
10-8. Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Angle Too Small
Correct Angle
10 - 30
Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
10-9. Electrode Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
1
2
2
3
Stringer Bead Steady

Movement Along Seam
Weave Bead Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide

area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
S-0054-A
OM-359 Page 73
10-10. Butt Joints

1
1
2
Tack Welds
Prevent edges of joint from drawing

together ahead of electrode by tack
welding the materials in position before final weld.
2
Square Groove Weld
Good for materials up to 3/16 in (5

mm) thick.
3
1/16 in
(1.6 mm)
30
Single V-Groove Weld
Good for materials 3/16 3/4 in

(5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
Create 30 degree angle of bevel on

materials in V-groove welding.
4
Double V-Groove Weld
Good for materials thicker than 3/16

in (5 mm).
S-0662
10-11. Lap Joint

30
Or Less
30
Or Less
1
1
2
Move electrode in circular motion.

3
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
Electrode
Single-Layer Fillet Weld
Multi-Layer Fillet Weld

S-0063 / S-0064
10-12. Tee Joint

1
2
Keep arc short and move at definite

rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
45
Or Less
Electrode
Fillet Weld
For maximum strength weld both

sides of upright section.
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
10-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-359 Page 74
10-13. Weld Test

1
2
3
Strike weld joint in direction shown.

A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
S-0057-B
10-14. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
10-15. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
OM-359 Page 75
10-16. Troubleshooting Incomplete Fusion
Incomplete Fusion failure of weld metal to fuse completely with

base metal or a preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
10-17. Troubleshooting Lack Of Penetration
Lack Of Penetration shallow fusion between weld metal and

base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.
10-18. Troubleshooting Excessive Penetration
Excessive Penetration weld metal melting through base metal and

hanging underneath weld.
Excessive Penetration
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-359 Page 76
10-19. Troubleshooting Burn-Through

Burn-Through weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
10-20. Troubleshooting Waviness Of Bead
Waviness Of Bead weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
10-21. Troubleshooting Distortion

Distortion contraction of weld metal during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-359 Page 77
26
25
23
24
. Hardware is common and
27
21
22
SECTION 11 PARTS LIST
45
46
47
8
7
11
9 10
60
55
61
62
59
52
54
56
53
63
24
57
2
1
51
50
48
43
12
44
38
13
42
14
15
10
37
16
35
36
40
17
39
33
34
19
18
20
32 31 30 29 28
41
not available unless listed.
802 609-K
802 609-K
Figure 11-1. Main Assembly

OM-359 Page 78
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly

. . . 1 . . . . . PC1 . . . . . 203 899
. . . . . . . . . . . . . . . . . . . . . . 186 914
. . . . . . . . PLG13, 15 . . . 131 054
. . . . . . . . . . PLG10 . . . . 130 203
. . . . . . . . . . PLG14 . . . . 115 092
. . . . . . . . . . PLG4 . . . . . 115 093
. . . . . . . . . . PLG17 . . . . 131 052
. . . . . . . . . . PLG16 . . . . 115 091
. . . 2 . . . . . . . . . . . . . . . . 195 778
. . . 3 . . . . . . . . . . . . . . . . 190 512
. . . 4 . . . . . PC2 . . . 190 734
. . . 5 . . . . . PC3 . . . 190 738
. . . 6 . . . . . . . . . . . . . . . . 207 562
. . . 7 . . . . . . G1 . . . . . . 199 854
. . . . . . . . . . . . . . . . . . . . . . 199 855
. . . . . . . . . . . . . . . . . . . . . . 199 856
. . . . . . . . . . . . . . . . . . . . . . 196 455
. . . 8 . . . . . . C3 . . . . . . 096 761
. . . 9 . . . . . . T3 . . . . . . 208 045
. . . 10 . . . C11, C19 . . . 195 552
. . . 11 . . . . . . R8 . . . . . . 188 067
. . . 12 . . . . . . . . . . . . . . 129 201
. . . 13 . . . . C20-23 . . 203 517
. . . 14 . . . . . . . . . . . . . . . . 207 574
. . . 15 . . . . . . . . . . . . . . . . 205 726
. . . 16 . . . . . . . . . . . . . . . . 201 019
. . . 17 . . . . . . . . . . . . . . . . 494 907
. . . 18 . . . . . . . . . . . . . . . . 204 389
. . . 19 . . . . . . . . . . . . . . . . 200 920
. . . 20 . . . . . . . . . . . . . . . . 200 922
. . . 21 . . . . . . . . . . . . . . +207 563
. . . 22 . . . . . . . . . . . . . . . . 168 343
. . . 23 . . . . . . . . . . . . . . . . 184 057
. . . . . . . . . . . . . . . . . . . . . . 189 491
. . . 24 . . . . . . . . . . . . . . . . 127 363
. . . 25 . . . . . . . . . . . . . . . . 168 384
. . . 26 . . . . . . . . . . . . . . . . 605 227
. . . 27 . . . . . GS1 . . . . . 133 873
. . . . . . . . . . . . . . . . . . . . . . 602 969
. . . 28 . . . . . . . . . . . . . . . . 010 146
. . . 29 . . . . . . . . . . . . . . . . 176 272
. . . 30 . . . . . . . . . . . . . . . . 184 058
. . . 31 . . . . . . 1T . . . . . . 199 312
. . . 32 . . . . . . . . . . . . . . . . 150 783
. . . 33 . . FM1, FM2 . . . 188 706
. . . 34 . . . . . . . . . . . . . . . . 187 807
. . . 35 . . . . . . . . . . . . . . . . 204 293
. . . 36 . . . . . . . . . . . . . . . . 026 627
. . . 37 . . . . T1, Z1 . . . . . 207 607
. . . 37 . . . . T1, Z1 . . . . . 207 710
. . . 37 . . . . T1, Z1 . . . . . 207 711
. . . . . . . . . . . TH1 . . . . . . 201 443
. . . . . . . . . . PLG1 . . . . . 202 119
. . . . . . . . . . PLG7 . . . . . 202 116
. . . . . . . . . . PLG8 . . . . . 202 117
. . . . . . . . . . PLG11 . . . . 202 118
. . . 38 . . . . . SR1 . . . . . 207 611
. . . 39 . . . . . . R2 . . . . . . 189 132
. . . 40 . . . . . . R1 . . . . . . 186 468
. . . 41 . . . . . . . . . . . . . . . . 194 590
. . . 42 . . . . . . . . . . . . . . +207 559
. . . 43 . . . . . . . . . . . . . . . . 207 571
. . . Circuit Card Assy, Interface (consisting of) . . . . . . . . . . . . . . . . . . . . . . .

. . . . Display, LED Numeric 7 Segment 3 Digit (LEDs 18 23) . . . . . . . . .
. . . Connector W/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Actuator Push Button Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Standoff, No 632 X .6406 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card, Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card, Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Spark Gap Assy, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Holder, Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Points, Spark Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor, Mica .002 UF 10,000 V Panel Mtg . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr, High Voltage 115v Pri 3600v Sec 30 Ma w/Term . . . . . . . . . . . . .
. . . Capacitor, Polyp Met Film 20. Uf 250 Vac 10% . . . . . . . . . . . . . . . . . . .
. . . Resistor, ww fxd 100 w 200 ohm w/clips . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor, polyp film 150 uf 250 VAC can 10% . . . . . . . . . . . . . . . . . . . .
. . . Panel, Left Wind Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning electric shock excess weight . . . . . . . . . . . . . . . . . . . . . .
. . . Screw, k50 x 20 pan hd trx pld pt thread forming . . . . . . . . . . . . . . . . .
. . . Holder, Torch/Cable (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Door, Torch/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Housing, Torch/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h . . . . . . . . . . . . . . .
. . . Door, Primary Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Spacer, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock And Incorrect Input P . . . . . . . . . . . . . . .
. . . Nut, 75014 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . .
. . . Plug, Protective No 6 Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . .
. . . Conn, Clamp Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Block, Terminal Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Blade, Fan 9.000 5wg 39deg .312 Bore Cw Plstc . . . . . . . . . . . . . . . . .
. . . Motor, Fan 230v 50/60hz 1550 Rpm .312 Dia Shaft . . . . . . . . . . . . . . .
. . . Bracket, Mtg Motor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Support, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Gasket, Lifting Eye Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr/Stabilizer Assy, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr/Stabilizer Assy, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr/Stabilizer Assy, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Thermistor, NTC 10k ohm @ 25 deg C 27.5 in lead . . . . . . . . . . . . . . . .
. . . Rectifier Assy, (Figure 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Resistor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Resistor, Ww Fxd 100 W 50 Ohm W/Clips . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Miller 12.563 X 5.376 Horizontal Syncrowav . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
6
2
1
1
1
1
1
4
4
1
1
2
1
1
4
4
1
1
2
1
2
4
1
1
2
2
2
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
OM-359 Page 79
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (continued)

. . . 44 . . . . . TE1 . . . . . . 202 790
. . . . . . . . . . . . . . . . . . . . . . 083 426
. . . . . . . . . . . . . . . . . . . . . . 038 618
. . . . . . . . . . . . . . . . . . . . . . 601 835
. . . . . . . . . . . . . . . . . . . . . . 601 836
. . . . . . . . . . . . . . . . . . . . . . 038 888
. . . . . . . . . . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . . . . 010 915
. . . . . . . . . . . . . . . . . . . . . . 602 207
. . . . . . . . . . . . . . . . . . . . . . 175 479
. . . . . . . . . . . . . . . . . . . . . . 213 248
. . . 45 . . . . C5, C6 . . . . 111 634
. . . 46 . . . . . . . . . . . . . . . . 155 436
. . . 47 . . . . . . S5 . . . . . . 207 236
. . . 48 . . . . . . S1 . . . . . . 128 757
. . . 50 . . . . . . . . . . . . . . . . 212 245
. . . . . . . . . . . . . . . . . . . . . . 143 397
. . . . . . . . . . . . . . . . . . . . . . 117 860
. . . . . . . . . . . . . . . . . . . . . . 107 983
. . . 51 . . . . . . . . . . . . . . . . 207 612
. . . 52 . . . . . . . . . . . . . . . . 174 991
. . . 53 . . . . . . . . . . . . . . +196 492
. . . 54 . . . . . . . . . . . . . . . . 203 990
. . . 55 . . . . . . . . . . . . . . . . 175 952
. . . 56 . . . . . . . . . . . . . . . . 204 776
. . . 56 . . . . . . . . . . . . . . . . 208 242
. . . 57 . . . . . . . . . . . . . . . . 207 572
. . . 59 . . . . . . . . . . . . . . . . 183 332
. . . 60 . . . . . . . . . . . . . . . . 204 416
. . . 61 . . . . . . . . . . . . . . . . 204 313
. . . 62 . . . . . . . . . . . . . . . . 204 307
. . . 63 . . . . . . . . . . . . . . . . 204 314
. . . Term Assy, Pri 1ph 3v (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . Terminal Board, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Link, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Stud, pri board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Stud, pri board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, flat brs .187 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . .
. . . . Washer, lock .255 ID x .489 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Link, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/Screw 2/O14 Wire .266std . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Ground/Protectiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Polarity/Changeover (DX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Tgl Dpst 60a 600vac Scr Term Wide Tgl . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Blank, Snapin Nyl .312 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HF Panel Assy, Lower (Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip.21 . . . . . . . . . . . . . . .
. . . Door, Access Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning General Precautionary Static&wire Fe . . . . . . . . . . . . .
. . . Plastic, Handle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Miller Syncrowave 250DX . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Miller Syncrowave 250DX (Wordless) . . . . . . . . . . . . . . . . .
. . . Door Spark Gap Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer .570 Dia X .125 Id W/Spring Clip . . . . . . . . . . . . . . . . . . .
. . . Drawer, Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Drawer, Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Slide, Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
12
4
2
6
6
4
2
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
3
1
1
2
1
OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-359 Page 80
Item
No.
Dia.
Mkgs.
Part
No.
207 612
. . . 1 . . . . . . . . . . . . . . . . 213 217
. . . 2 . . . . . . . . . . . . . . . . 208 294
. . . 3 . RC2/CB1/C12 . 207 617
. . . . . . . . . . . . . . . . . . . . . . 156 734
. . . 4 . . . . . RC1 . . . . . 211 911
. . . . . . . . . . PLG5 . . . . . 143 976
. . . 6 . . . . . . . . . . . . . . . . 089 120
. . . 7 . . . . . . . . . . . . . . . . 155 527
. . . 8 . . . . . . . . . . . . . . . . 208 408
. . . 9 . . . . . . . . . . . . . . . . 207 560
. . . 10 . . . . . . T4 . . . . . . 212 251
. . . . . . . . . . . . . . . . . . . . . . 203 474
. . . 11 . . . C13, C14 . . . 206 878
. . . 12 . . . . . . . . . . . . . . . . 039 047
Description
Quantity
Figure 11-2. HF Panel Assembly, Lower (Figure 11-1 Item 51)

. . . Panel, Lower Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Connector, Faston Male 4-Prong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, W/Leads And Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nut, 01032 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . .
. . . Conn, circ ms/cpc 14 skt size 20 rcpt w/filtering . . . . . . . . . . . . . . . . . . .
. . . Clamp, Hose .375 .450 Clp Dia Slfttng Green . . . . . . . . . . . . . . . . . . .
. . . Hose, Nprn Brd No 1 X .250 Id X 28.000 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Ftg, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Standoff W/Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Coil, Hf Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Service Kit, DX Coupling Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
1
1
2
2
803 165-B
Figure 11-2. HF Panel Assembly, Lower
OM-359 Page 81
Item
No.
Dia.
Mkgs.
Part
No.
207 611
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
. . . . . . . . . . . . . . . . 206 984
. . . . . . . . . . . . . . . . 207 558
. . . . . . . . . . . . . . . . 196 355
. . . . . . . . . . . . . . . . 211 441
. . . . . . . . . . . . . . . . 207 575
. . . . . . . . . . . . . . . . 199 962
. . C7, 8, 9, 10 . . 190 460
. . . . . HD1 . . . . . 191 941
. . . Mod 1, 2 . . . . 196 760
. . . . . TH2 . . . . . . 206 327
. . . . . . R3 . . . . . . 211 440
Description
Quantity
Figure 11-3. HF Rectifier Assembly (Figure 11-1 Item 38)

. . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Clip, Snap In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Right Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current Hall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Thyristor, SCR Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Thermister, NTC 30K Ohm @ 25 deg C . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Resistor, WW Fxd 400 W 35 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . .
1
1
4
3
1
1
2
1
2
1
1
803 164-A
Figure 11-3. Rectifier Assembly
OM-359 Page 82
Effective January 1, 2002

(Equipment with a serial number preface of LC or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts 3 Years Labor
*
*
2.
3 Years Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers

Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year whichever is greater.)
4.
6 Months Batteries
5.
90 Days Parts
*
*
MIG Guns/TIG Torches

Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Millers True Blue Limited Warranty shall not apply to:

1.
Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.
3.
Equipment that has been modified by any party other

than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customers risk and expense. Millers option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/02
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for:
Welding Supplies and Consumables

Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during

shipment.
For assistance in filing or settling claims,

contact your distributor and/or equipment
manufacturers Transportation Department.
PRINTED IN USA
2002 Miller Electric Mfg. Co.
5/02

Miller Syncrowave 250dx

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OM-359

Arc Welding Power Source

And Non-CE Models

Visit our website at

From Miller to You

Working as hard as you do

Miller offers a Technical

Miller Electric manufactures a full line

The following terms are

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC

SECTION 9 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

Declaration of Conformity For

Miller Electric Mfg. Co.

Declares that the product:

1635 W. Spencer Street

conforms to the following Directives and Standards:

Mr. Danilo Fedolfi, Managing Director

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possible

1-2. Arc Welding Hazards

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

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

D Wear a safety harness if working above floor level.

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

D Clamp work cable with good metal-to-metal contact to workpiece

ELECTRIC SHOCK can kill.

D Insulate work clamp when not connected to workpiece to prevent

SIGNIFICANT DC VOLTAGE exists after removal of

D Do not touch live electrical parts.

D Do not drape cables over your body.

FUMES AND GASES can be hazardous.

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

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

HOT PARTS can cause severe burns.

MAGNETIC FIELDS can affect pacemakers.

WELDING can cause fire or explosion.

FLYING METAL can injure eyes.

D Pacemaker wearers keep away.

NOISE can damage hearing.

CYLINDERS can explode if damaged.

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

MOVING PARTS can cause injury.

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

D Keep away from moving parts such as fans.

FALLING UNIT can cause injury.

H.F. RADIATION can cause interference.

D Use lifting eye to lift unit only, NOT running

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.