Miller INTELLITIG 4 Owner's manual

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

Off

On

Off

On

Off

±5 Amperes

±10 Amperes

±20 Amperes

±40 Amperes

On

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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