Intellitig 4
Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
Programmable Precision DC TIG
Controller
OM-2803C 144 084C
January 1999
With An Inverter Power Source:
Visit our website at
www.MillerWelds.com
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
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.
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Control Unit 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Typical Process Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Setting DIP Switch SW1 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Installing Gas Supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Connecting Remote Pendant 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Remote 14 Receptacle Information And Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Function Of User Relays 1 And 2 (Use Is Optional) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. User Relay Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Weld Input And Output Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Connecting Input Power 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Safety Equipment 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Work Clamp 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Digital Display 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Program/Run/Reset Keyed Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Mode Selector Switch 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Parameter Select Push Button 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Right/Increase Push Button 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Left/Decrease Push Button 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Purge Push Button 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Gas Control And Flow Rate Meter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Power Switch 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Remote Pendant 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Shielding Gas 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Adjusting Spark Gaps 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – INTRODUCTION TO PROGRAMMING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Introduction 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Modes Of Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PROGRAMMING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. General 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Automatic Mode 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Semi-Automatic Mode 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Manual GTAW Mode 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. SMAW Mode 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Editing A Program 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Dry Run Feature 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Stop Watch Feature 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Linking Programs 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Combining Programs 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – SEQUENCE OF OPERATION 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Gas Tungsten Arc Welding (GTAW) In The Automatic Mode 43. . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Gas Tungsten Arc Welding (GTAW) In The Semi-Automatic Modes 43. . . . . . . . . . . . . . . . . . .
8-3. Gas Tungsten Arc Welding (GTAW) In The Manual Mode 46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Shielded Metal Arc Welding (SMAW) 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Executing Linked Programs 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Executing Combined Programs 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Shutting Down 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – DIAGNOSTICS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Introduction 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Diagnostics Program 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – ELECTRICAL DIAGRAMS 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 – HIGH FREQUENCY 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 – TUNGSTEN ELECTRODE 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Selecting Tungsten Electrode 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Preparing Tungsten 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 – PARTS LIST 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
OM-2803 Page 1
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
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.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
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
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conduc-
tor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
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 Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists 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.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
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
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-2803 Page 2
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.
ARC RAYS can burn eyes and skin.
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 mate-
rial (leather and wool) and foot protection.
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.
WELDING can cause fire or explosion.
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.
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.
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.
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.
CYLINDERS can explode if damaged.
D Protect compressed gas cylinders from excessive heat, mechani-
cal 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 fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-2803 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
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.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-2803 Page 4
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 electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-2803 Page 5
SECTION 2 – SPECIFICATIONS
2-1. Control Unit
Specification Description
Welding Processes Gas Tungsten Arc (GTAW), Shielded Metal Arc (SMAW) Welding
Welding Circuit Rating 250 Amperes At 100% Duty Cycle
Type Of Input Power When Used With 115 Volts: 115 Volts AC Single-Phase 50/60 Hz, 1.0 Amperes
When Used With 230 Volts: 230 Volts AC Single-Phase 50/60 Hz, 0.5 Amperes
Overall Dimensions Height: 9-1/8 in (232 mm); Width: 9-1/2 in (241 mm); Length: 19-1/4 in (489 mm)
Weight Net: 30 lb (13.6 kg); Ship: 37 lb (16.8 kg)
OM-2803 Page 6
SECTION 3 – INSTALLATION
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services,
computers, and communications equipment.
• Have only qualified person familiar with electronic equipment perform this installation.
• Read and follow entire Section 11 for proper location and installation requirements for high-frequency equipment before installing
unit.
swarn13.1 4/93
3-1. Typical Process Connections
ST-800 505 / ST-800 504
1 Welding Power Source
2 Gas Cylinder
3 Control Unit
4 Remote Pendant Control
5 Torch
6 Work Clamp
7 Foot Control
8 Electrode Holder
For GTAW Welding
For SMAW Welding
1
3
4
5
67
8
2
3
6 7
1
OM-2803 Page 7
3-2. Setting DIP Switch SW1
WARNING
ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Turn Off welding power source and control unit, and
disconnect input power before setting DIP switches.
STATIC ELECTRICITY can damage
parts on circuit boards.
• Put on grounded wrist strap BEFORE handling
boards or parts.
fwarn2.1* 9/91 / fwarn5.1* 9/91
ST-146 842 / ST-800 506
Set DIP switch positions as follows:
1 Front Panel
2 Retaining Screw
Loosen retaining screw, and open
hinged front panel.
3 Microprocessor Board PC1
4 DIP Switch SW1
Factory default settings shown. To
set a position, depress the end near
the desired choice.
5 Positions 1 And 2
In Automatic and Semi-Automatic
1, weld amperage can be adjusted
up or down during weld using re-
mote pendant. Define amperage
adjustment range limits by setting
positions 1 and 2 according to table.
6 Position 3
Use position 3 to select whether
pulses are defined as time or fre-
quency values.
Set Off to define as frequency.
Set On to define as time.
7 Position 4
Set Off to run diagnostics program.
Set On to stop diagnostics pro-
gram, and for all other operations.
8 Positions 7 And 8
Set 7 and 8 according to table to se-
lect Semi-Automatic Modes 1 thru
5.
Close front panel and tighten retain-
ing screw after setting SW1.
12345678
Position
On
On
Off
Off
On
Off
On
Off
±5 Amperes
±10 Amperes
±20 Amperes
±40 Amperes
On
On
Off
Off
On
Off
On
Off
1
Position
2
Position
7
Position
8
Defined
Amperage
Adjustment
Limit
Defined
Semi-Automatic
Mode
*1
2
3
4
*5On On
*Semi-Automatic 1 mode is defined when
remote Stop switch is connected. Semi-
Automatic 5 mode is defined when remote Stop
switch is not connected.
Off
5
8
6
= On
4
7
Positions 5 and 6 are not used.
Tools Needed:
1
2
3
OM-2803 Page 8
3-3. Installing Gas Supply
WARNING
CYLINDERS can explode if damaged.
• Keep cylinders away from welding and other
electrical circuits.
• Never touch cylinder with welding electrode.
• Always secure cylinder to running gear, wall, or
other stationary support.
BUILDUP OF SHIELDING GAS can harm
health or kill.
• Shut off shielding gas supply when not in use.
warn4.1 9/91
Allowable pressure range for shielding gas input is 30-50 psi (207 to 345 kPa).
NOTE
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
Install so face is vertical.
5 Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
6 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
7 Gas In Fitting
8 Gas Out Fitting
The Gas In and Gas Out fittings
have 5/8-18 right-hand threads.
Obtain proper size, type, and length
hose and make connections as fol-
lows:
Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect shielding gas hose from
torch to Gas Out fitting.
ssb3.3* 6/93 – ST-146 841-A / Ref. ST-158 697-A / Ref. ST-140 732
Tools Needed:
1
2
3
45
6
Argon Gas
5/8, 1-1/8 in
7
8
To Torch
OM-2803 Page 9
3-4. Connecting Remote Pendant
1 Remote Pendant
2 Remote 4 Receptacle RC2
3 Keyway
4 Plug
5 Threaded Collar
Use receptacle to connect supplied
remote pendant. User-wired con-
trols equivalent to remote control
are also connected to this
receptacle.
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
Socket Information:
A Normally closed contact with socket C opens
when pendant Stop button is pressed.
B Normally open contact with socket C closes when
pendant Decrease button is pressed.
C +24 volts dc.
D Normally open contact with socket C closes when
pendant Start/Increase button is pressed.
sb7.1* 8/92 – ST-146 841-A / Ref. ST-140 732 / ST-146 839 / Ref. S-0446-A
DA
CB
1
4
5
2
3
REMOTE 4
3-5. Remote 14 Receptacle Information And Connections
Socket Information:
Remote Contactor
A +24 volts dc.
B Contact closure to pin A completes +24 volts dc
contactor control circuit.
Remote Amperage/Voltage Control
C Command reference; +10 volts dc.
D Control circuit common.
E Input command signal (potentiometer wiper or 0 to
+10 volts dc).
The remaining sockets are not used.
sb7.1* 8/92 – ST-146 841-A / Ref. ST-140 732 / Ref. S-0004-A / S-0750
1 Remote 14 Receptacle RC3
2 Keyway
3 Plug
4 Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
3
4
AJ
B
K
I
C
L
NH
D
M
G
E
F
1
2
REMOTE 14
OM-2803 Page 10
3-6. Function Of User Relays 1 And 2 (Use Is Optional)
Ref. SB-139 983
User relays 1 and 2 can be used to
control external devices, such as
fixtures.
When enabled, relay 1 changes
states according to programmed
time delay values in the Automatic,
Semi-Automatic 1, and Semi-Auto-
matic 5 modes. In the remaining
modes, relay 1 is not functional.
The relay is also not functional if
disabled.
1 Start Delay Range
The programmed start delay value
determines how long after the Start/
Increase push button is pressed
user relay 1 will energize. The
range of acceptable values is 0.0 to
120.0 seconds. In order to function
properly, the start delay value must
not delay energization beyond the
end of weld/peak current.
2 Stop Delay Range
The programmed stop delay value
determines how long after weld/
peak current ends user relay 1 will
deenergize. The range is 0.0 to
120.0 seconds.
The stop delay time cannot delay
deenergization of user relay 1
beyond the end of postflow.
Initial
Current
Weld/Peak
Current
Initial
Slope
Final
Slope
Final
Current
Preflow
Postflow
1
Initial
Current
Weld/Peak
Current
Initial
Slope
Final
Slope
Final
Current
Preflow
Postflow
2
Initial
Current
Weld/Peak
Current
Initial
Slope
Final
Slope
Final
Current
Preflow
Postflow
1
2
1 Relay 2 Energizes
2 Relay 2 Deenergizes
Relay 2 energizes when initial cur-
rent starts if an arc is detected, and
deenergizes when final current
ends. If an arc is not detected, relay
2 does not energize.
In Automatic mode and Semi-Auto-
matic modes 1 and 5, relay 2
changes state only if the relay is en-
abled during programming. In Se-
mi-Automatic modes 2, 3, and 4,
relay 2 changes state whether en-
abled or not.
User Relay 1
User Relay 2
OM-2803 Page 11
3-7. User Relay Connections
WARNING
ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Turn Off welding power source and control unit, and
disconnect input power before making user relay
connections.
STATIC ELECTRICITY can damage
parts on circuit boards.
• Put on grounded wrist strap BEFORE handling
boards or parts.
fwarn2.1* 9/91 / fwarn5.1* 9/91
ST-146 841-A / ST-800 506 / Ref. SB-139 983
When making connections to user
relay contacts, use #28 to #18
AWG solid or stranded insulated
wire. Do not strip insulation from
end of wire before making connec-
tions. The contacts are rated at 5
amperes, 230 volts each.
Open front panel and remove top
from unit.
1 Strain Relief Connector
Loosen strain relief and insert
wires. Route wires to desired termi-
nals (see table).
2 Interface Board PC3
3 Terminal Assembly (Six Total)
4 Lever Up
5 Wire Insertion Hole
6 Lever Down
For each connection, lift terminal le-
ver, insert wire, and push terminal
lever down to locked position.
Tighten strain relief when all con-
nections are made. Reinstall top,
and close front panel.
Connect leads to external devices.
To avoid high frequency interfer-
ence, route leads away from weld
cables.
3
Connection On
Terminal Strip
1
2
3
4
5
6
Function
User Relay #2 N.O. Contact
User Relay #2 Common
User Relay #2 N.C. Contact
User Relay #1 N.O. Contact
User Relay #1 Common
User Relay #1 N.C. Contact
N.O. = normally open
N.C. = normally closed
4
5
6
1
2
OM-2803 Page 12
3-8. Weld Input And Output Connections
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off control unit and welding power source, and disconnect input power before making connections.
swarn12.1* 2/92
1 Positive Input Plug
Connect weld cable from positive
(+) terminal on welding power
source to Positive Input plug.
2 Negative Input Plug
Connect weld cable from negative
(–) terminal on welding power
source to Negative Input plug.
GTAW DC Electrode Negative/
Straight Polarity (DCEN)
3 Torch Receptacle
Connect torch cable.
4 Positive (+) Receptacle
Connect one end of work cable,
connect remaining end to work-
piece.
For DC Electrode Positive (DCEP),
reverse cable connections.
SMAW DC Electrode Positive/
Reverse Polarity (DCEP)
4 Positive (+) Receptacle
Connect electrode holder cable.
5 Negative (–) Receptacle
Connect one end of work cable,
connect remaining end to work-
piece.
For DC Electrode Negative
(DCEN), reverse cable connec-
tions.
ssb2.2 11/92 – Ref. S-0752 / ST-146 841-A
Tools Needed:
3/4 in
Input Plug Connections
Output Receptacle Connections For GTAW Welding
Output Receptacle Connections For SMAW Welding
Positive (+)
Negative (–)
1
2
Positive (+) Negative (–)
Torch
4
5
Positive (+) Negative (–)
Torch
4
3
OM-2803 Page 13
3-9. Connecting Input Power
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off control unit and welding power source, and disconnect input power before inspecting or installing.
• Have only qualified persons install unit.
• Installation must meet National Electrical Code and all other codes.
swarn3.1* 2/93
A. To Power Source Receptacle Information And Connections
Socket Information:
A Provides connection to program-controlled relay contact internal
to control unit; contact makes connection with relay contact con-
nected to pin B to energize welding power source.
B Contact closure to pin A completes contactor control circuit.
D Control circuit common with respect to pin E.
E Provides 0 to +10 volt dc command signal with respect to pin D.
G 115 volts ac circuit common; also connected to welding power
source chassis.
I Up to 1.0 amperes of 115 volts ac, 60 Hz, with respect to socket
G (circuit common).
K Machine chassis (circuit common).
The remaining sockets are not used.
sb7.1* 8/92 – ST-146 841-A / Ref. S-0004-A / S-0750
1 To Power Source Receptacle
RC1
2 Keyway
3 Plug
4 Threaded Collar
Connections to this receptacle re-
quire an interconnecting cord that is
suitable for the welding power
source being used with the control
unit.
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar. See Section 3-9B
for instructions on connecting the
remaining end of the interconnect-
ing cord to the welding power
source.
3
4
1 2
AJ
B
K
I
C
L
NH
D
M
G
E
F
OM-2803 Page 14
B. Interconnecting Cord Connections
ST-800 288
Depending on welding power
source used, select and obtain
interconnecting cord and make
connections as follows:
1 Interconnecting Cord With
14-Pin Plug Only
Connect to Remote 14 receptacle
on welding power source. Align key-
way, insert plug, and tighten
threaded collar.
2 Interconnecting Cord With
14-Pin Plug And 115 Volt AC
Plug
Connect 14-pin plug to Remote 14
receptacle on welding power
source. Align keyway, insert plug,
and tighten threaded collar.
Insert 115 volt ac plug into 115 volt
ac duplex receptacle.
3 Interconnecting Cord With
5-Pin Plug And 115 Volt AC
Plug
Connect 5-pin plug to Remote 5 re-
ceptacle on welding power source.
Align keyway, insert plug, and tight-
en threaded collar.
Insert 115 volt ac plug into 115 volt
ac duplex receptacle.
1
2
3
C. Changing Jumper Links For 230 Volts Operation
ST-800 506
For applications requiring 230 volts
input power, proceed as follows:
Open front panel, and remove top
cover.
Route suitable customer-supplied
input power cable thru strain relief
on rear panel. Disconnect existing
leads 1 and 2 (circuit common) from
Power switch S1, and connect new
cable leads to same S1
terminals.
Change jumper links positions as
follows:
1 Input Voltage Label
2 Input Terminal Board TE1
3 Input Voltage Jumper Links
Move links as shown on label.
Reinstall top cover, and close front
panel.
1
1/4 in
Tools Needed:
2
3
230 VOLTS
S-072 212-A
115 VOLTS
OM-2803 Page 15
SECTION 4 – OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Do not touch live electrical parts.
• Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion.
• Do not weld near flammable material.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not weld on closed containers.
• Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with correct shade of filter.
• Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
• Keep away from moving parts.
• Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
• Pacemaker wearers keep away.
• Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
See Safety Precautions at beginning of manual for ba-
sic welding safety information.
swarn6.1 10/91
4-1. Controls
1 Power Switch (On Rear
Panel)
2 Digital Display
3 Right/Increase Push Button
4 Parameter Select Push Button
5 Mode Switch
6 Program/Run/Reset Keyed
Switch
7 Left/Decrease Push Button
8 Purge Push Button
9 Gas Control
10 Gas Flow Rate Meter
11 Remote Pendant
ST-800 503 / Ref. ST-146 839
11
12
3
4
5
6
10
9
8
7
4-2. Safety Equipment
1 Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct shade
of filter (see ANSI Z49.1).
sb3.1 10/91
123
OM-2803 Page 16
4-3. Work Clamp
1 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93
Tools Needed:
1
4-4. Digital Display
1 Digital Display
Depending on the mode and pro-
grammed options, the digital dis-
play either shows the steps in the
welding program or weld output.
Program Displays
Use display to enter and read val-
ues. If weld program steps are
shown during operation, the pro-
grammed time values decrease as
process time runs out.
Weld Output Metering
If selected during programming, the
digital display shows weld output
amperage and voltage values as
the weld program is carried out.
Weld output metering is always ac-
tive when a Manual GTAW or
SMAW program is carried out.
If the voltage value exceeds 99.9
volts, the display shows OVR.
1
Ref. ST-139 983
4-5. Program/Run/Reset Keyed Switch
1 Program/Run/Reset Keyed
Switch
Use switch for selecting these three
functions:
Program
Use to enter, change, and/or ex-
ecute a program.
Run
Use to execute a program only. Key
can be removed to prevent unau-
thorized access to program.
Reset
Use before switching between Run/
Program positions when unit is On.
For example, use Program position
to enter program, move to Reset
momentarily, and move to Run to
execute program. Remove key if
desired. If changing program, move
to Reset momentarily before mov-
ing back to Program.
1
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