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Miller Mark VI, KH331461 Owner's manual

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OM-2211
April1997
Miller
The
Power
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~'
~
Eff.
w/Senal
Number
KH331461
Processes
~
Shielded
Metal
Arc
(Stick)
Welding
~
DC-Gas
Tungsten
Arc
(DC-TIG)
Welding
~
Flux
Cored
Arc
Welding
and
Gas
Metal
Arc
Welding
(MIG)
Spray
Transfer
with
Voltage-
Sensing
Feeder
~
Air
Plasma
Cutting
and
Gouging
with
Spectrumfi
Plus
Air
Carbon
Arc
Cutting
and
Gouging
Description
Multiple
Operator
Arc
Welding
Power
Source
J~JJ~ll~J~
y]
0~
Visit
our
website
at
www.mfflerweids.com
OWNERS
MANUAL
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
Neils
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
Electric
manufactures
a
full
line
of
welders
and
welding
related
equipment.
For
information
on
other
quality
Miller
products,
contact
your
local
Miller
distributor
to
receive
the
latest
full
line
catalog
or
individual
catalog
sheets.
To
locate
your
nearest
distributor
call
1-800-4-A-Miller.
From
~
to
You
.
iIkiIFIIIII
~
REGISTERED
QUALITY
SYSTEM
Miller
is
the
first
welding
equipmeNt
manufacturer
iN
the
U.S.A.
to
be
registered
to
tbe
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.
_
.
p7/A
Miller.
w
ThePwer~fBbie.
Description
This
heavy-duty
multiple
operator
welding
(MOW)
system
drives
six
modules
from
a
single
main
transformer
and
single
3-phase
input.
Each
welding
module
features
built-in
remote
control,
a
wide
range
of
amperage
settings,
excellent
Stick
welding
characteristics,
as
well
as
true
multipro
cess
capabilities.
Modules
can
be
paralleled
for
extra
welding
power.
The
Mark
VI
operates
24
hours
a
day
with
exceptional
durability
and
productivity.
Housed
in
a
rugged
steel
enclosure,
the
unit
can
withstand
the
punishment
of
the
worst
weather
and
construction
site
elements.
Features
Six
modules
driven
by
one
transformer,
can
be
paralleled
for
higher
output
Each
module
can
be
connected
for
either
DC
straight
of
reverse
polarity
(consult
ANSI
Z49.1,
Section
4,
and
OSHA,
29
CFR1
91
0,
subpart
0,
before
connecting)
Includes
two
115
volt
AC
GFCI
auxiliary
power
receptacles
Work
connections
are
electrically
isolated
from
the
frame
Reduced
footprint
and
weight,
transports
as
a
single
unit
Product
features
and
specifications
are
subject
to
change
without
notice
Processes
Shielded
Metal
Arc
(Stick)
Welding
DC-Gas
Tungsten
Arc
(DC-TIG)
Welding
Flux
Cored
Arc
Welding
and
Gas
Metal
Arc
Welding
(MIG)
Spray
Transfer
with
Voltage-
sensing
Feeder
Air
Plasma
Cutting
and
Gouging
with
Spectrumfi
Plus
Air
Carbon
Arc
Cutting
and
Gouging
The
following
terms
are
used
interchangeably
throughout
this
manual:
TIG
=
GTAW
Stick
=
SMAW
Miller
offers
a
Technical
Manual
9
which
provides
more
detailed
seivice
and
paris
information
for
21
your
unit.
To
obtain
a
Technical
Manual
contact
your
local
21
distributor~
Your
distributor
can
also
supply
you
with
Welding
Process
Manuals
such
as
SMAW,
GTAW,
24
GMAW,
and
GMAW-P
For
practical
information
on
weld
ing,
process
applications,
and
Miller
products,
visit
our
website
at
CaH
1
-800-4-A-MILLER
for
your
local
Miller
distributor.
Your
distributor
gives
you
Service
You
always
get
the
fast,
reliable
response
you
need.
Most
replacement
parts
can
be
in
your
hands
in
24
hours.
Support
Need
fast
answers
to
the
tough
welding
questions?
Contact
your
distributor.
The
expertise
of
the
distributor
and
Miller
is
there
to
help
you,
every
step
of
the
way.
Table
of
CoNtents
Section
Page
1.
Safety
Precautions
1
1.
Consignes
de
sØcuritØ
5
2.
Installation
3.
Operation
4.
Maintenance
and
Troubleshooting
5.
Electrical
Diagram
6.
Parts
List
26
Warranty
www.nd~wekIs.com
S
S
1.
Safety
Precautions
Read
Before
Using
1.1:
SymbollUsage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
~
Means
Note;
not
safely
related.
1.2
Arc
Welding
Hazards
A
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.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A
During
operation,
keep
everybody,
especially
children,
away.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
bums.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
danger
of
falling.
S
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Always
verify
the
supply
ground
check
and
be
sure
that
input
power
cord
ground
wire
is
properiy
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properiy
grounded
receptacle
outlet.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
drape
cables
over
your
body.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
Use
onlywell-maintained
equipment.
Repairor
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
Wear
a
safety
harness
if
working
above
floor
level.
Keep
all
panels
and
covers
securely
in
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
~
.J
FUMESANDGASEScanbehzardous.
Keep
your
head
Out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instructions
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watch-
person
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-221
1
-
4/97,
sat
ety_som
4/97
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.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
OM-221
1
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
bum
eyes
and
skin.
Sparks
fly
oft
from
the
weld.
Weara
welding
helmetfitted
with
a
proper
shade
of
filterto
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.i
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields
under
your
helmet.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
oft
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe before
doing
any
welding.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.1
(see
Safety
Standards).
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING
METAL
can:
injure
eyes.
Welding,
chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
Wear
approved
safety
glasses
with
side
shields
even
under
your
welding
helmet.
BUILDUP
OF
GAS
can
injure
or
kill
Shutoff
shielding
gas
supply
when
not
in
use.
Always
ventilate
confined
spaces
or
use
approved
air-supplied
respirator.
HOT
PARTS
can
cause
severe
burns
Do
not
touch
hot
parts
bare
handed.
Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affet
pacemakers~
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
NOISE
can
damage
hearing.
Noise
from
some
processes
or
equipment
can
damage
hearing.
Wear
approved
ear
protection
if
noise
level
is
high.
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.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
Keep
protective
cap
in
place
overvalve
except
when
cylinder
is
in
use
or
connected
for
use.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
S
2
OM-221
1
1
5
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):.
. .
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
in
terpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
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
the
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
possible.
About
Pacemakers:
The
above
procedures
are
also
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
.
4
OM-2211
1.
Consignes
do
sØcuritØ
lire
avant
utilisation
1 1
Signification
des
symboles
4A
Signifie
Mise
en
garde!
Soyez
vigilant!
Cette
procedure
presente
des
risques
de
danger!
Ceux-ci
sont
identifies
par
des
symboles
adjacents
aux
directives.
A
Identifie
un
message
de
sØcuritØ
particulier.
ffT
Signifie
NOTA
nestpas
re!atif
Ia
sØcuritØ.
1
2
Dangers
relattfs
au
soudage
a
Iarc
A
Les
symboles
presentØs
ci-aprŁs
sont
utilisØs
tout
au
long
du
present
manuel
pour
attirer
votre
attention
et
identifier
les
risques
de
danger.
Lorsque
vous
voyez
un
symbole,
soyez
vigilant
et
suivez
les
directives
mentionnØes
afin
dØviter
tout
danger.
Les
consignes
de
sØcuritØ
prØsentØes
ci-aprŁs
ne
font
que
rØsumer
linformation
contenue
dans
les
normes
de
sØcuritØ
ØnumØrØes
a
Ia
section
1-5.
Veuillez
lire
et
respecter
toutes
ces
normes
de
sØcuritØ.
A
Linstallation,
lutilisation,
lentretien
et
les
reparations
ne
doi
vent
Øtre
confiØs
qua
des
personnes
qualifiees.
A
Au
cours
de
lutilisation,
tenirtoute
personne
a
lØcart
et
plus
par
ticuliŁrement
les
enfants.
UN
CHOC
ELECTRIQUE
peuttuer.
Un
simple
contact
avec
des
piŁces
electnques
peut
provoquer
une
electrocution
ou
des
blessures
graves.
LØlectrode
et
le
circuit
de
soudage
sont
sous
tension
des
que
lappareil
est
sur
ON.
Le
circuit
dentrØe
et
les
circuits
intemes
de
lappareil
sont
egalement
sous
tension
ace
moment-l.
En
soudage
semi-automatique
ou
automatique,
le
fil,
le
dØvidoir,
le
logement
des
galets
dentraTnement
et
les
piŁces
metalliques
en
contact
avec
le
fil
de
soudage
sont
sous
tension.
Des
matØriels
ma!
installØs
ou
ma!
mis
a
Ia
terre
prØsentent
un
danger.
Ne
jamais
toucher
les
piŁces
electnques
sous
tension.
Porter
des
gants
et
des
vŒtements
de
protection
secs
ne
comportant
pas
de
trous.
Sisoler
de
Ia
piŁce
et
de
Ia
terre
au
moyen
de
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empØcher
le
contact
phy
sique
Łventuel
avec
Ia
piŁce
ou
Ia
terre.
~e
passe
servir
de
source
electnque
courant
electnque
dans
les
zones
humides,
dans
les
endroits
confines
ou
l
oCi
on
risque
de
tomber.
Se
servir
dune
source
electrique
courant
electrique
UNIQUEMENT
site
procedØ
de
soudage
le
demande.
Si
lutilisation
dune
source
Ølectrique
courant
electrique
savere
neces
saire,
se
servir
de
Ia
fonction
de
tØlØcommande
51
lappareil
en
eSt
equipe.
Couperlalimentation
ou
arrØter
to
moteuravant
de
procØder
a
linstal
lation,
a
Ia
reparation
ou
a
lentretien
de
lappareil.
DØverrouiller
lalimentation
selon
Ia
norme
OSHA
29
CFR
1910.147
(voir
nomies
de
sØcuritØ).
Installeret
mettro
a
laterre
correctement
cet
appareil
conformement
son
manuel
dutilisation
et
aux
codes
nationaux,
provinciaux
et
municipaux.
Toujours
verifier
Ia
terre
du
cordon
dalimentation
Verifieret
sassu
rer
que
left!
do
terre
du
cordon
dalimentation
esi
bien
raccordØ
ala
bome
de
terre
du
sectionnourou
que
Ia
fiche
du
cordon
est
raccordØe
a
une
pnse
correctement
mise
a
Ia
terre.
En
effectuant
les
raccordements
dentrØe
fixer
dabord
le
conducteur
de
mise
a
Ia
terre
appropnŁ
et
contre-vŁrtfier
les
connexions.
VeriflerfrŁquemmentle
cordon
dalimentation
pourvoir
sit
nest
pas
endommage
ou
dØnudŁ
remplacer
le
cordon
immØdiatement
sit
est
endommage
un
cable
dŁnudØ
peut
provoquer
une
electrocution.
Mettre
lappareil
hors
tension
quand
on
ne
lutilise
pas.
Ne
pas
utiliser
des
cables
uses,
endommages,
de
grosseur
insuffi
sante
ou
ma]
Øpisses.
Ne
pas
enrouler
les
cables
autour
du
corps.
Si
Ia
piŁce
soudØe
dolt
Œtre
mise
a
laterre,
le
faire
directement
avec
un
cable
distinct
ne
pas
utiliser
le
connecteur
do
piŁce
ou
10
cable
de
retour.
Ne
pas
toucher
lØ!ectrode
quand
on
est
en
contact
avec
Ia
piŁce,
a
terre
ou
une
electrode
provenant
dune
autre
machine.
ri
~
Ce
groupe
do
symboles
signifie
Mise
en
garde!
Soyez
vigilant
iiy
a
des
nsques
de
danger
relies
aux
CHOCS
ELECTRIQUES,
aux
PIECES
EN
MOUVEMENTet
aux
PIECES
CHAUDES.
Reportez-vous
aux
symboles
et
aux
directives
ci-dessous
attn
de
connaitre
les
mesures
a
prendre
pour
Øviter
tout
danger.
Nutiliser
quun
materiel
en
bon
Øtat.
Reparer
ou
remplacer
sur-le
champ
les
piŁces
endommagees.
Entretenir
lappareil
conformement
ace
manuel.
Porter
un
hamais
de
sØcuntØ
quand
on
travaille
en
hauteur.
Maintenir
solidement
en
place
tous
es
panneaux
et
capots.
Fixer
le
cable
de
retour
do
faon
a
obtenir
un
bon
contact
mØtal-mØtal
avec
Ia
piŁce
a
souderou
Ia
table
do
travail,
le
plus
prŁs
possible
do
a
soudure.
Isoler
Ia
pince
de
masse
quand
pas
mis
a
Ia
piŁce
pour
Øviter
le
contact
avec
tout
objet
mØtallique.
Ily
a
DU
COURANT
CONTINU
IMPORTANT
dans
les
convertisseurs
aprŁs
Ia
suppression
de
Ialimenta
tion
electrique.
ArrOter
les
convertisseurs,
dŁbrancher
le
cou
rant
Ølectnque,
01
dØ
charger
es
condensateurs
dalimentation
selon
es
instructions
indiquØes
dans
Ia
partie
entrotien
avant
de
toucher
los
piŁces.
I
~
LES
FUMEES
ET
LES
GAZ
peuvent
I
~
Œtre
dangereux.
L__
~W
Le
soudage
genŁre
des
fumØes
et
des
gaz.
Leur
W
inhalation
peut
Œtro
dangereux
pour
votre
sante.
--
Eloigner
votre
tŒte
des
fumØes.
Ne
pas
respirer
les
fumØes.
A
lintØrieur,
ventiler
Ia
zone
etlou
utiliser
un
Øchappement
au
ni
veau
do
Iarc
pour
lØvacuation
des
fumØes
et
des
gaz
de
soudage.
Si
Ia
ventilation
est
insuffisante,
utiliser
un
respirateur
a
alimenta
tion
dair
homo!oguØ.
Lire los
specifications
do
sØcurftØ
des
matØnaux
(MSDS5)
01
los
ins
tructions
du
fabncant
concemant
Ies
mŁtaux,
les
consommables,
es
revØtements,
es
nettoyants
et
les
dŁgraisseurs.
Travail!er
dans
un
espace
fermØ
seu!ement
sil
est
bien
ventilØ
ou
en
portant
un
respirateur
a
alimentation
dair.
Demander
toujours
a
un
surveillant
dment
formØ
dose
tenir
a
proximite.
Des
fumØes
et
des
gaz
do
soudage
peuvent
dØplacer
lair
et
abaisser
le
niveau
doxygeno
provoquarit
dos
btossures
ou
des
accidents
mortets.
Sassurer
que
lair
de
respiration
no
presente
aucun
danger.
Ne
pas
souder
dans
des
end
roits
situØs
a
proximitØ
dopØrations
do
degraissage,
de
nettoyage
ou
do
pulvØnsation.
La
chaleur
et
los
rayons
de
Iarc
peuvent
rØagir
en
presence
de
vapeurs
ot
former
des
gas
hautemont
toxiques
et
irritants.
No
pas
soudor
des
mŁtaux
munis
dun
revŒtement,
tots
que
lacier
galvanisØ,
plaque
en
p10mb
ou
au
cadmium
a
moms
quo
!e
revŒto
ment
nait
ØtØ
enlevØ
dans
Ia
zone
do
soudure,
quo
lendroit
soit
bien
ventilØ,
et
si
nØcessaire,
en
portant
un
respirateur
a
alimenta
tion
dair.
Los
revŒtements
et
tous
les
mØtaux
renferrnant
ces
ØlØ
ments
peuvent
degager
des
fumees
toxiques
en
cas
de
soudage.
safety_som_fre
4197
OM-2211
5
LES
RAVONS
DE
LARC
peuvent
pro
voquerdes
brGirØs
dens
in
yeux
et
sur
Ia
peau
Le
rayonnement
de
larc
du
procØdØ
de
soudage
gØnŁre
des
rayons
visibles
et
invisibles
intenses
(ultraviolets
et
infrarouges)
susceptibles
de
provoquer
des
brOlures
dans
les
yeux
et
sur
Ia
peau.
Des
Øtincelles
sont
projetOes
pendant
le
soudage.
Porter
un
casque
de
soudage
muni
dun
Łcran
de
filtre
appropriŁ
pour
protØgervotre
visage
et
vos
yeux
pendant
le
soudage
ou
pour
regar
der
(voirANSi
Z49.1
et
Z87.1
enumOrŁ
dans
les
normes
de
securitØ).
Porter
des
protections
approuvŁs
pour
les
oreilles
si
le
niveau
sondre
est
trop
ØlevŁ.
Utiliser
des
Łcrans
ou
des
barriŁres
pour
proteger
des
tiers
de
lŁclair
et
de
leblouissement;
demander
aux
autres
personnes
de
ne
pas
re
garder
lam.
Porter
des
vºtements
de
protection
constituO
dans
une
matiOre
dura
ble,
resistant
au
feu
(cuir
ou
lame)
et
une
protection
des
pieds.
m.~I
LE
SOUDAGE
peut
prØvoquer
tin
I
k
~%-~i
incendie
ou une
explosion.
~
Le
soudage
effectuŁ
sur
des
conteneurs
formØs
tels
que
des
reservoirs,
tambours
ou
des
conduites
peut
provoquerleurØclatement. DesØtincellespeuventetre
projetOes
de
arc
de
soudure.
La
projection
dOtincel
les,
des
piŁces
chaudes
et
des
Øquipements
chauds
peut
provoquerdes
incendies
et
des
brUlures.
Le
contact
accidentel
de
lOlectrode
avec
des
objets
metalliques
peut
provoquer
des
Øtincelles,
une
explosion,
un
surchauffement
ou
un
incendie.
Avant
de
commencer
le
soudage,
verifier
et
sassurer
que
lendroit
ne
prØsente
pas
de
danger.
Se
proteger
et
dautres
personnes
de
Ia
projection
detincelles
et
de
metal
chaud.
Ne
pas
souder
dans
un
endroit
l
oU des
Øtincelles
peuvent
tomber
sur
des
substances
inflammables.
DØplacertoutes
les
substances
mnflammables
a
une
distance
de
10,7
m
de
larc
de
soudage.
En
cas
dimpossibilitO
les
recouvrir
soigneuse
ment
avec
des
protections
homologuØs.
Des
etincelles
et
des
materlaux
chauds
du
soudage
peuvent
facile
ment
passer
dans
dautres
zones
en
traversant
de
petites
fissures
et
des
ouvertures.
Surveillertout
dOclenchementdincendie
ettenirun
extincteura
proxi
mite.
Le
soudage
effectuŁ
sur
un
plafond,
plancher,
paroi
ou
separation
peut
dØclencher
un
incendie
de
lautre
cate.
Ne
pas
effectuer
le
soudage
sur
des
conteneurs
fermes
tels
que
des
reservoirs,
tambours,
ou
conduites,
a
moms
quils
naient
OtŁ
prØpa
rŁs
correctement
conformement
a
AWS
F4.1
(voir
les
normes
de
sØcurftO).
Brancher
le
cable
sur
Ia
piŁce
le
plus
prŁs
possible
de
Ia
zone
de
sou
dage
pour
Łviter
le
transport
du
courant
sur
une
longue
distance
par
des
chemins
inconnus
Łventuels
en
provoquant
des
risques
dŁlec
trocution
et
dincendie.
Ne
pas
utiliser
le
poste
de
soudage
pour
degeler
des
conduites
ge
lees.
En
cas
de
non
utilisation,
enlever
Ia
baguette
dŁlectrode
du
porte-
electrode
ou
couper
le
fil
a
Ia
pointe
de
contact.
Porter
des
vŒtements
de
protection
dØpourvus
dhuile
tels
que
des
gants
en
cuir,
une
chemise
en
materiau
lourd,
des
pantalons
sans
re
vera,
des
chaussures
hautes
et
un
couvre
chef.
Avant
de
souder,
retirer
toute
substance
combustible
de
vos
poches
telles
quun
allumeur
au
butane
ou
des
allumettes.
~L:fI
DES
PAR11CULES
VOLANTES
_____
peuvent
blesser
les
yeux~.
Le
soudage,
lØcaillement,
le
passage
de
Ia
piŁce
a
Ia
brosse
en
flu
de
fer,
et
le
meulage
gene
rent
des
etincelles
et
des
particules
metalliques
volan
tes.
Pendant
Ia
periode
de
refroidissement
des
soudures,
elles
risquent
de
projeter
du
laitier.
Porter
des
lunettes
de
sØcuritØ
avec
Øcrans
latØraux
ou
un
ecran
facial.
LES
ACCUMULATIONS
DE
GAZ
ris
qtiØntde
provoquerdes
blessuresl
mØrne
Ia
mort.
:
..
:
-
Fermer
lalimentation
du
gaz
protecteur
en
cas
de
non
utilisation.
Veiller
toujours
a
bien
aØrer
es
espaces
confines
ou
se
servir
dun
respi
rateur
dadduction
dair
homologuØ.
DES
PI¨CES
CHAUPES
peuvent
pro-.:
voquer
desbrOlureSgravØs.
Ne
pas
toucher
des
parties
chaudes
a
mains
nues
PrØvoir
une
pØriode
de
refroidissement
avant
dutiliser
le
pistolet
ou
Ia
torche.
I
I
LES
CHAMPS
MAGNETIQUES
peuvent
I
affecter
les
stirnulateurs
cardiaques.
Porteursde
stimulateurcardiaque,
restez
a
distance.
Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consulter
leur
mOdecin
avant
de
sapprocher
des
operations
de
soudage
a
larc,
de
gougeage
ou
de
soudage
par
points.
LE BRUIT
peut
affecter
rouTe.
Le
bruit
des
processus
et
des
Øquipements
peut
affecter
Iouie.
Porter
des
protections
approuves
pour
es
oreilles
si
le
niveau
sondre
est
trop
ØlevO.
SI
des
BOUTEILLESsont
endomma
gees,
elles
pourront
exploser.
Des
bouteilles
de
gaz
protecteur
contiennent
du
gaz
sous
haute
pression.
Si
une
bouteille
est
endomma
I
-
I
gee,
elIe
peutexploser.
Du
fail
que
les
bouteilles
de
gaz
font
normalement
partie
du
procede
de
soudage,
les
manipuler
avec
precaution.
ProtOger
es
bouteilles
de
gaz
comprime
dune
chaleur
excessive,
des chocs
mecaniques,
du
laitier,
des
flammes
ouvertes,
des
etin
celles
et
des
arcs.
Placer
les
bouteilles
debout
en
es
fixant
dans
un
support
station
naire
ou
dans
un
porte-bouteilles
pour
les
empŒcher
de tomber
ou
de
se
renverser.
Tenir
les
bouteilles
eloignØes
des
circuits
de
soudage
ou
autres
cir
cuits
Ølectriques.
Ne
jamais
placer
une
torche
de
soudage
sur
une
bouteille
a
gaz.
Une
electrode
de
soudage
ne
doit
jamais
entrer
en
contact
avec
une
bouteille.
Ne
jamais
souder
une
bouteiule
pressurisØe
risque
dexplosion.
Utiliser
seulement
des
bouteilles
de
gaz
protecteur,
regulateurs,
tuyaux
et
raccords
convenables
pour
cette
application
spØcifique;
es
mamntenir
ainsi
que
les
elements
associØs
en
bon
Otat.
Ne
pas
tenir
Ia
tŒte
en
face
de
Ia
sortie
en
ouvrant
Ia
soupape
de
Ia
bouteulle.
Maintenir
le
chapeau
de
protection
sur
Ia
soupape,
sauf
en
cas
dutilisation
ou
de
branchement
de
Ia
bouteille.
Lire
et
suivre
les
instructions
concemant
les
bouteilles
de
gas
com
prime,
les
Øquipements
associes
et
es
publications
P-i
CGA
enu
merees
dans
les
normes
de
securite.
6
OM-2211
23
Duty
Cycle
and
Overheating
~I~fl
~JJ~J
2000
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load without
overheating.
If
unit
overheats,
thermostat(s)
opens,
output
stops,
and
cooling
fan
runs.
Wait
fifteen
minutes
for
unit
to
cool.
Reduce
amperage
or
voltage,
or
duty
cycle
before
welding.
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
The
main
transformer
of
the
poly
weld
system
has
dual
duty
cycle
ratings,
each
for
a
specific
amper
age
output
range.
If
the
unit
is
oper
ated
in
the
750
ampere
range,
the
unit
is
rated
at
100%
duty
cycle.
This
means
the
polyweld
system
can
be
operated
at
750
amperes
continuously.
When
the
unit
is
op
erated
in
the
1500
ampere
range,
it
is
rated
at
25%
duty
cycle.
The
sum
of
the
outputs
of
each
module
should
not
exceed
the
rated
duty
cycle
of
the
main
trans
former.
For
example,
the
polyweld
system
can
be
safely
operated
at
a
load
of
1000
amperes
at
80
per
cent
duty
cycle.
This
value
could
be
obtained
by
operating
four
mod
ules
at
a
load
of
250
amperes
at
80
percent
duty
cycle,
or
by
operating
six
modules
at
a
load
of
167
amperes
at
80
percent
duty
cycle.
E
~LEJ~I
EACH
MODULE
OUTPUT
EE
Single
Module
60%
Duty
Cycle
at
250
Amperes
Overheating
~>AorV
Reduce
Duty
Cycle
.
dutyl
4195SB-i
84
107
U)
1500
1400
1200
~
1100
1000
o
400
250
200
150
10
15
20
25
30
40
50
60708090100
X
DUTY
CYCLE
Main
Transformer
100%
Duty
Cycle
at
750
Amperes
0*
Continuous
Welding
Main
Transformer
25%
Duty
Cycle
at
1500
Amperes
2-1/2
Minutes
Welding
7-1/2
Minutes
Resting
6
Minutes
Welding
4
Minutes
Resting
Minutes
10
OM-221
1
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
pow
er
supply.
bc_i
3/96
Ref.
ST-801
627
A
High
center
of
gravity
always
securely
tie
down
unit
with
ade
quate
chains
or
other
proper
re
straints
when
moving
to
pre
vent
tipping.
Do
not
place
unit
where
it
could
tip.
3.
Location
And
Airflow
36
in
(920mm)
Air
In
1
Lifting
Eye
2
Lifting
Forks
Movement
2
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
36
in
(920mm)
Air
Out
U~PORTANT
This
unit
contains
fan
blades
with
different
airflow
directions
to
provide
proper
cooling
of
components.
Consult
Owners
Manual
for
correct
Part
No.
and
location.
S-183
992
Do
not
block
airflow
to
sides
of
unit.
OM-221
1
11
2.~7
Weld
Cable
Sizes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
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.
Contact
your
distributor
for
the
mm2
equivalent
weld
cable
sizes.
28
Common
Work
Cable
Sizes
Common
Work
Cable
Sizes
At
Main
Transformer
Rated
Welding
Current
Cable
Length
Cable
Size
50ft(15m)
2No.3/0
lOOft(30.5m)
2No.4/0
150ft(46m)
3No.3/0
200ft(61m)
3No.4/0
Welding
Amperes
10
60%
Duty
Cycle
60100%
Duty
Cycle
100
ft
(30
m)
Or
Less
150ft
(45
m)
200ft
I
250ft
(60
m)
(70
m)
300
ft~T
350ft
400ft
(90
m)
j
(105
m)
(120
m)
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3 2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
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
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
800
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
900
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
1000
2-2/0
2-3/0
2-4/0 3-3/0
4-3/0
4-4/0
1250
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1500
2-4/0
3-3/0 3-4/0
4-4/0
4-4/0
1750
750
1000
2-750
2-1000
2-1000
OM-2211
13
2
9
Safety
InformatIon
for
Connecting
to
Weld
Output
Terminals
ri:~
A
ELECTRIC
SHOCK
can
kill;
ARCING
can
burn
skin
or
damage
electrical
connections.
Turn
Off
welding
power
source
before
rnaking
any
weld
output
connections.
Do
not
connect
welding
output
of
different
polarities
to
the
same
structure.
See
ANSI
Z49.1
and
OSHA
Title
29,
Chapter
XVII,
Part
1910,
Subpart
0
(addresses
at
beginning
of
manual).
When
Positive
or
Negative
weld
output
terminal
is
jumper
linked
to
the
Common
Work
terminal
and
the
work
cable
is
connected
to
the
Common
Work
Connection
panel,
do
not
connect
a
cable
between
the
remaining
weld
output
terminal
and
the work.
Remove
jumper
link
from
any
module
where
work
and
electrode
connections
are
made
directly
to
the
Positive
and
Negative
output
terminals.
Do
not
handle
or
come
in
contact
with
two
live
electrodes
at
the
same
time.
Connect
all
paralleled
modules
for
the
same
polarity.
ELECTRIC
SHOCK
can
kill;
TWO
TIMES
NORMAL
OPEN-CIRCUIT
VOLTS
exist
between
electrode
holders
of
opposite
polarity.
Do
not
touch
electrode
holders
of
opposite
polarity
at
the
same
time.
Separate
electrode
holders
of
opposite
polarity
to
prevent
contact.
Consult
ANSI
Z49.1
for
common
grounding
safe
practices.
2.10
Weld
Output
Terminals
Ref.
ST-801
627
A
Read
and
understand
safety
information
in
Section
2.9
before
proceeding.
1
Handle
2
Positive
(+)
Weld
Output
Terminal
3
Negative
()
Weld
Output
Terminal
4
Weld
Output
Terminal
Cover
(Typical
For
All
Weld
Output
Terminals)
Cover
all
weld
output
terminals
with
weld
output
terminal
covers.
Go
to
Section
2.11
and/or
2.12
for
standard
module
weld
output
con
nections,
or
Section
2.13
and/or
2.14
for
parallel
module
weld
output
connections.
14
OM-2211
2
11
Standard
Module
Weld
Output
Connections
without
Common
Work
Terminal
Ref.
ST-801
641
~
Tools
Needed:
A
Read
and
understand
safety
information
in
Section
2.9
before
proceeding.
See
Section
2.7
for
proper
cable
size.
1
Electrode
Holder
Cable
2
Work
Cable
For
Electrode
Positive
(Reverse
Polarity/DCEP),
connect
work
cable
to
Negative
()
terminal
and
electrode
holder
cable
to
Positive
(+)
terminal
(see
Section
2.10).
For
Electrode
Negative
(Straight
PolarttyfDCEN),
reverse
cable
connections.
3
Weld
Output
Terminal
Cover
(Typical
For
All
Weld
Output
Terminals)
Cover
all
weld
output
terminals
with
weld
output
terminal
covers.
3/4,7/8
in
2
OM-221
1
15
A
Read and
understand
safety
information
in
Section
2.9
before
proceeding.
See
Section
2.7
for
proper
cable
size.
1
Electrode
Holder
Cable
2
Work
Jumper
Cable
3
Common
Work
Terminal
4
Common
Work
Cable
For
Electrode
Positive
(Reverse
Polarity/DCEP),
connect
work
jumper
cables
from
Negative
()
terminals
to
Common
Work
termi
nal,
and
connect
electrode
holder
cables
to
Positive
(+)
terminals
(see
Section
2.10).
For
Electrode
Negative
(Straight
Polarity/DCEN),
connect
work
jumper
cables
from
Positive
(+)
ter
minals
to
Common
Work
terminal,
and
connect
electrode
holder
cables
to
Negative
()
terminals
(see
Section
2.10).
Connect
as
many
modules
as
re
quired.
Do
not
exceed
duty
cycle
of
machine.
5
Cable
Restraint
Route
cables
through
restraints
as
shown.
6
Weld
Output
Terminal
Cover
(Typical
For
All
Weld
Output
Terminals)
Cover
all
weld
output
terminals
with
weld
output
terminal
covers.
212
StandardModule
Weld
Output
Connections
with
Common
Work
Terminal
A
INADEQUATE
WORK
CABLE
CONNECTIONS
can
cause
serious
damage
to
input
power
service
and
create
a
hazardous
condition.
Connect
a
weld
cable
of
adequate
size
between
the
Com
mon
Work
Connection
and
the
workpiece
whenever
any
module(s)
is
connected
to
use
the
Common
Work
terminal.
Ref.
ST-801
641
Do
not
exceed
duty
cycle
of
machine.
Tools
Needed:
~
For
common
work
connect
ion,
work
cable
must
be
able
to
cony
combined
weld
~
3/4,
7/8
in
output
of
all
modules
using
the
Common
Work
Terminal
(see
Section
2.8
for
prop
er
cable
size).
The
Common
Work
Terminal
is
isolated
from
the
unit
frame.
16
OM-2211
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