Miller LA106279 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
Processes
Description
Multiprocess Welding
OM-818 183 577C
March 2000
Inverter Rack
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 donโt have time to do it any other way.
Thatโs 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 couldnโt 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. Theyโre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Ownerโs 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. Weโve
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, thereโs 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
โ 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.
TABLE OF CONTENTS
SECTION 1 โ 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 1 โ CONSIGNES DE SECURITE โ LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage ร lโarc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplรฉmentaires en relation avec lโinstallation, le fonctionnement
et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sรฉcuritรฉ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs รฉlectromagnรฉtiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 โ INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications For Racks Used With XMT 304 Models 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Specifications For Racks Used With Invision Or Phoenix 456 Models 9. . . . . . . . . . . . . . . . . .
2-3. Selecting A Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Installing Welding Power Source Onto Rack 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Welding Power Source Input Power Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Selecting Cable Sizes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Common Work Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Paralleling Welding Power Sources For SMAW 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Connecting Input Power To Rack 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Electrical Service Guide For XMT 304 4-Racks 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Electrical Service Guide For XMT 304 6-Racks 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Electrical Service Guide For Phoenix/Invision 456 Racks 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 โ MAINTENANCE & TROUBLESHOOTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Routine Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Overload Protection 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 โ ELECTRICAL DIAGRAMS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
OM-818
OM-818 Page 1
SECTION 1 โ SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
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 โNoteโ; 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
Ownerโs Manual and national, state, and local codes.
D Always verify the supply ground โ 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 โ double-check connections.
D Frequently inspect input power cord for damage or bare wiring โ
replace cord immediately if damaged โ 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.
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
manufacturerโs 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-818 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 โ 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-818 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 โ 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-818 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: โThe body of evidence, in the
committeeโs judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.โ
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-818 Page 5
SECTION 1 โ CONSIGNES DE SECURITE โ LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procรฉdure
prรฉsente des risques de danger ! Ceux-ci sont identifiรฉs
par des symboles adjacents aux directives.
Y Identifie un message de sรฉcuritรฉ particulier.
. Signifie NOTA ; nโest pas relatif ร la sรฉcuritรฉ.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliรฉs aux CHOCS รLECTRIQUES, aux PIรCES EN
MOUVEMENT et aux PIรCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaรฎtre les mesures ร prendre pour
รฉviter tout danger.
1-2. Dangers relatifs au soudage ร lโarc
Y Les symboles prรฉsentรฉs ci-aprรจs sont utilisรฉs tout au long du
prรฉsent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnรฉes afin dโรฉviter tout danger. Les
consignes de sรฉcuritรฉ prรฉsentรฉes ci-aprรจs ne font que rรฉsumer
lโinformation contenue dans les normes de sรฉcuritรฉ รฉnumรฉrรฉes
ร la section 1-4. Veuillez lire et respecter toutes ces normes de
sรฉcuritรฉ.
Y Lโinstallation, lโutilisation, lโentretien et les rรฉparations ne doi-
vent รชtre confiรฉs quโร des personnes qualifiรฉes.
Y Au cours de lโutilisation, tenir toute personne ร lโรฉcart et plus par-
ticuliรจrement les enfants.
UN CHOC รLECTRIQUE peut tuer.
Un simple contact avec des piรจces รฉlectriques peut
provoquer une รฉlectrocution ou des blessures graves.
Lโรฉlectrode et le circuit de soudage sont sous tension
dรจs que lโappareil est sur ON. Le circuit dโentrรฉe et les
circuits internes de lโappareil sont รฉgalement sous
tension ร ce moment-lร . En soudage semi-automatique ou automatique,
le fil, le dรฉvidoir, le logement des galets dโentraรฎnement et les piรจces
mรฉtalliques en contact avec le fil de soudage sont sous tension. Des
matรฉriels mal installรฉs ou mal mis ร la terre prรฉsentent un danger.
D Ne jamais toucher les piรจces รฉlectriques sous tension.
D Porter des gants et des vรชtements de protection secs ne comportant
pas de trous.
D Sโisoler de la piรจce et de la terre au moyen de tapis ou dโautres
moyens isolants suffisamment grands pour empรชcher le contact phy-
sique รฉventuel avec la piรจce ou la terre.
D Ne pas se servir de source รฉlectrique ร courant รฉlectrique dans les zones
humides, dans les endroits confinรฉs ou lร oรน on risque de tomber.
D Se servir dโune source รฉlectrique ร courant รฉlectrique UNIQUEMENT si le
procรฉdรฉ de soudage le demande.
D Si lโutilisation dโune source รฉlectrique ร courant รฉlectrique sโavรจre nรฉces-
saire, se servir de la fonction de tรฉlรฉcommande si lโappareil en est รฉquipรฉ.
D Couper lโalimentation ou arrรชter le moteur avant de procรฉder ร lโinstal-
lation, ร la rรฉparation ou ร lโentretien de lโappareil. Dรฉverrouiller
lโalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sรฉcuritรฉ).
D Installer et mettre ร la terre correctement cet appareil conformรฉment ร
son manuel dโutilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vรฉrifier la terre du cordon dโalimentation โ Vรฉrifier et sโassu-
rer que le fil de terre du cordon dโalimentation est bien raccordรฉ ร la
borne de terre du sectionneur ou que la fiche du cordon est raccordรฉe
ร une prise correctement mise ร la terre.
D En effectuant les raccordements dโentrรฉe fixer dโabord le conducteur
de mise ร la terre appropriรฉ et contre-vรฉrifier les connexions.
D Vรฉrifier frรฉquemment le cordon dโalimentation pour voir sโil nโest pas
endommagรฉ ou dรฉnudรฉ โ remplacer le cordon immรฉdiatement sโil est
endommagรฉ โ un cรขble dรฉnudรฉ peut provoquer une รฉlectrocution.
D Mettre lโappareil hors tension quand on ne lโutilise pas.
D Ne pas utiliser des cรขbles usรฉs, endommagรฉs, de grosseur insuffi-
sante ou mal รฉpissรฉs.
D Ne pas enrouler les cรขbles autour du corps.
D Si la piรจce soudรฉe doit รชtre mise ร la terre, le faire directement avec un
cรขble distinct.
D Ne pas toucher lโรฉlectrode quand on est en contact avec la piรจce, la
terre ou une รฉlectrode provenant dโune autre machine.
D Nโutiliser quโun matรฉriel en bon รฉtat. Rรฉparer ou remplacer sur-le-
champ les piรจces endommagรฉes. Entretenir lโappareil conformรฉment
ร ce manuel.
D Porter un harnais de sรฉcuritรฉ quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le cรขble de retour de faรงon ร obtenir un bon contact mรฉtal-mรฉtal
avec la piรจce ร souder ou la table de travail, le plus prรจs possible de la
soudure.
D Isoler la pince de masse quand pas mis ร la piรจce pour รฉviter le contact
avec tout objet mรฉtallique.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs aprรจs la suppression de lโalimenta-
tion รฉlectrique.
D Arrรชter les convertisseurs, dรฉbrancher le courant รฉlectrique, et dรฉ-
charger les condensateurs dโalimentation selon les instructions
indiquรฉes dans la partie entretien avant de toucher les piรจces.
Le soudage gรฉnรจre des fumรฉes et des gaz. Leur
inhalation peut รชtre dangereux pour votre santรฉ.
D Eloigner votre tรชte des fumรฉes. Ne pas respirer
les fumรฉes.
D A lโintรฉrieur, ventiler la zone et/ou utiliser un รฉchappement au niveau
de lโarc pour lโรฉvacuation des fumรฉes et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur ร alimenta-
tion dโair homologuรฉ.
D Lire les spรฉcifications de sรฉcuritรฉ des matรฉriaux (MSDSs) et les
instructions du fabricant concernant les mรฉtaux, les consomma-
bles, les revรชtements, les nettoyants et les dรฉgraisseurs.
D Travailler dans un espace fermรฉ seulement sโil est bien ventilรฉ ou en
portant un respirateur ร alimentation dโair. Demander toujours ร un
surveillant dรปment formรฉ de se tenir ร proximitรฉ. Des fumรฉes et des
gaz de soudage peuvent dรฉplacer lโair et abaisser le niveau dโoxy-
gรจne provoquant des blessures ou des accidents mortels. Sโassu-
rer que lโair de respiration ne prรฉsente aucun danger.
D Ne pas souder dans des endroits situรฉs ร proximitรฉ dโopรฉrations de
dรฉgraissage, de nettoyage ou de pulvรฉrisation. La chaleur et les
rayons de lโarc peuvent rรฉagir en prรฉsence de vapeurs et former des
gaz hautement toxiques et irritants.
D Ne pas souder des mรฉtaux munis dโun revรชtement, tels que lโacier
galvanisรฉ, plaquรฉ en plomb ou au cadmium ร moins que le revรชte-
ment nโait รฉtรฉ enlevรฉ dans la zone de soudure, que lโendroit soit bien
ventilรฉ, et si nรฉcessaire, en portant un respirateur ร alimentation
dโair. Les revรชtements et tous les mรฉtaux renfermant ces รฉlรฉments
peuvent dรฉgager des fumรฉes toxiques en cas de soudage.
LES FUMรES ET LES GAZ peuvent
รชtre dangereux.
OM-818 Page 6
Le rayonnement de lโarc du procรฉdรฉ de soudage
gรฉnรจre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brรปlures dans les yeux et sur la peau. Des รฉtincelles sont projetรฉes
pendant le soudage.
LES RAYONS DE LโARC peuvent pro-
voquer des brรปlures dans les yeux et
sur la peau.
D Porter un casque de soudage muni dโun รฉcran de filtre appropriรฉ pour
protรฉger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 รฉnumรฉrรฉ dans les normes de sรฉcuritรฉ).
D Porter des protections approuvรฉs pour les oreilles si le niveau sondre est
trop รฉlevรฉ.
D Utiliser des รฉcrans ou des barriรจres pour protรฉger des tiers de lโรฉclair
et de lโรฉblouissement; demander aux autres personnes de ne pas re-
garder lโarc.
D Porter des vรชtements de protection constituรฉ dans une matiรจre dura-
ble, rรฉsistant au feu (cuir ou laine) et une protection des pieds.
Le soudage effectuรฉ sur des conteneurs fermรฉs tels
que des rรฉservoirs, tambours ou des conduites peut
provoquer leur รฉclatement. Des รฉtincelles peuvent รชtre
projetรฉes de lโarc de soudure. La projection dโรฉtincel-
les, des piรจces chaudes et des รฉquipements chauds peut provoquer des
incendies et des brรปlures. Le contact accidentel de lโรฉlectrode avec des
objets mรฉtalliques peut provoquer des รฉtincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vรฉrifier
et sโassurer que lโendroit ne prรฉsente pas de danger.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
D Se protรฉger et dโautres personnes de la projection dโรฉtincelles et de
mรฉtal chaud.
D Ne pas souder dans un endroit lร oรน des รฉtincelles peuvent tomber sur
des substances inflammables.
D Dรฉplacer toutes les substances inflammables ร une distance de 10,7
m de lโarc de soudage. En cas dโimpossibilitรฉ les recouvrir soigneuse-
ment avec des protections homologuรฉs.
D Des รฉtincelles et des matรฉriaux chauds du soudage peuvent facile-
ment passer dans dโautres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout dรฉclenchement dโincendie et tenir un extincteur ร proxi-
mitรฉ.
D Le soudage effectuรฉ sur un plafond, plancher, paroi ou sรฉparation
peut dรฉclencher un incendie de lโautre cรดtรฉ.
D Ne pas effectuer le soudage sur des conteneurs fermรฉs tels que des
rรฉservoirs, tambours, ou conduites, ร moins quโils nโaient รฉtรฉ prรฉpa-
rรฉs correctement conformรฉment ร AWS F4.1 (voir les normes de
sรฉcuritรฉ).
D Brancher le cรขble sur la piรจce le plus prรจs possible de la zone de sou-
dage pour รฉviter le transport du courant sur une longue distance par
des chemins inconnus รฉventuels en provoquant des risques dโรฉlec-
trocution et dโincendie.
D Ne pas utiliser le poste de soudage pour dรฉgeler des conduites ge-
lรฉes.
D En cas de non utilisation, enlever la baguette dโรฉlectrode du porte-
รฉlectrode ou couper le fil ร la pointe de contact.
D Porter des vรชtements de protection dรฉpourvus dโhuile tels que des
gants en cuir, une chemise en matรฉriau lourd, des pantalons sans re-
vers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles quโun allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D Le soudage, lโรฉcaillement, le passage de la piรจce
ร la brosse en fil de fer, et le meulage gรฉnรจrent
des รฉtincelles et des particules mรฉtalliques vo-
lantes. Pendant la pรฉriode de refroidissement des soudures, elles ris-
quent de projeter du laitier.
D Porter des lunettes de sรฉcuritรฉ avec รฉcrans latรฉraux ou un รฉcran facial.
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
mรชme la mort.
D Fermer lโalimentation du gaz protecteur en cas de
non utilisation.
D Veiller toujours ร bien aรฉrer les espaces confinรฉs ou se servir dโun respi-
rateur dโadduction dโair homologuรฉ.
DES PIรCES CHAUDES peuvent pro-
voquer des brรปlures graves.
D Ne pas toucher des parties chaudes ร mains nues
D Prรฉvoir une pรฉriode de refroidissement avant
dโutiliser le pistolet ou la torche.
LES CHAMPS MAGNรTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez ร distance.
D Les porteurs dโun stimulateur cardiaque doivent
dโabord consulter leur mรฉdecin avant de sโapprocher
des opรฉrations de soudage ร lโarc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter lโouรฏe.
Le bruit des processus et des รฉquipements peut affecter
lโouรฏe.
D Porter des protections approuvรฉs pour les oreilles si
le niveau sondre est trop รฉlevรฉ.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gรฉe, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procรฉdรฉ de soudage, les
manipuler avec prรฉcaution.
D Protรฉger les bouteilles de gaz comprimรฉ dโune chaleur excessive,
des chocs mรฉcaniques, du laitier, des flammes ouvertes, des รฉtin-
celles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnai-
re ou dans un porte-bouteilles pour les empรชcher de tomber ou de
se renverser.
D Tenir les bouteilles รฉloignรฉes des circuits de soudage ou autres cir-
cuits รฉlectriques.
D Ne jamais placer une torche de soudage sur une bouteille ร gaz.
D Une รฉlectrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressurisรฉe โ risque dโexplosion.
D Utiliser seulement des bouteilles de gaz protecteur, rรฉgulateurs,
tuyaux et raccords convenables pour cette application spรฉcifique;
les maintenir ainsi que les รฉlรฉments associรฉs en bon รฉtat.
D Ne pas tenir la tรชte en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas dโuti-
lisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz com-
primรฉ, les รฉquipements associรฉs et les publications P-1 CGA รฉnu-
mรฉrรฉes dans les normes de sรฉcuritรฉ.
Si des BOUTEILLES sont endomma-
gรฉes, elles pourront exploser.
OM-818 Page 7
1-3. Dangers supplรฉmentaires en relation avec lโinstallation, le fonctionnement
et la maintenance
Risque DโINCENDIE OU
DโEXPLOSION.
D Ne pas placer lโappareil sur, au-dessus ou ร proxi-
mitรฉ de surfaces infllammables.
D Ne pas installer lโappareil ร proximitรฉ de produits inflammables
D Ne pas surcharger lโinstallation รฉlectrique โ sโassurer que lโalimen-
tation est correctement dimensionnรฉ et protรฉgรฉ avant de mettre
lโappareil en service.
LA CHUTE DE LโAPPAREIL peut
blesser.
D Utiliser lโanneau de levage uniquement pour sou-
lever lโappareil, NON PAS les chariot, les bouteil-
les de gaz ou tout autre accessoire.
D Utiliser un engin dโune capacitรฉ appropriรฉe pour
soulever lโappareil.
D En utilisant des fourches de levage pour dรฉplacer lโunitรฉ, sโassurer
que les fourches sont suffisamment longues pour dรฉpasser du cรดtรฉ
opposรฉ de lโappareil.
LโEMPLOI EXCESSIF peut
SURCHAUFFER LโรQUIPEMENT.
D Prรฉvoir une pรฉriode de refroidissement, respec-
ter le cycle opรฉratoire nominal.
D Rรฉduire le courant ou le cycle opรฉratoire avant de
recommancer le soudage.
D Ne pas obstruer les passages dโair du poste.
LES CHARGES รLECTROSTATI-
QUES peuvent endommager les cir-
cuits imprimรฉs.
D รtablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des piรจces.
D Utiliser des pochettes et des boรฎtes antistatiques
pour stocker, dรฉplacer ou expรฉdier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas sโapprocher des organes mobiles.
D Ne pas sโapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent pro-
voquer des blessures.
D Ne pas appuyer sur la gachette avant dโen avoir
reรงu lโinstruction.
D Ne pas diriger le pistolet vers soi, dโautres person-
nes ou toute piรจce mรฉcanique en engageant le fil
de soudage.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Rester ร lโรฉcart des organes mobiles comme le
ventilateur.
D Maintenir fermรฉs et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
LE RAYONNEMENT HAUTE FRร-
QUENCE (H.F.) risque de provoquer
des interfรฉrences.
D Le rayonnement haute frequence peut provoquer
des interfรฉrences avec les รฉquipements de ra-
dioโnavigation et de communication, les services
de sรฉcuritรฉ et les ordinateurs.
D Demander seulement ร des personnes qualifiรฉes familiarisรฉes
avec des รฉquipements รฉlectroniques de faire fonctionner lโinstalla-
tion.
D Lโutilisateur est tenu de faire corriger rapidement par un รฉlectricien
qualifiรฉ les interfรฉrences rรฉsultant de lโinstallation.
D Si le FCC signale des interfรฉrences, arrรชter immรฉdiatement lโappa-
reil.
D Effectuer rรฉguliรจrement le contrรดle et lโentretien de lโinstallation.
D Maintenir soigneusement fermรฉs les portes et les panneaux des
sources de haute frรฉquence, maintenir les รฉclateurs ร une distance
correcte et utiliser une terre et et un blindage pour rรฉduire les interfรฉ-
rences รฉventuelles.
LE SOUDAGE ร LโARC risque de
provoquer des interfรฉrences.
D Lโรฉnergie รฉlectromagnรฉtique risque de provoquer
des interfรฉrences pour lโรฉquipement รฉlectronique
sensible tel que les ordinateurs et lโรฉquipement
commandรฉ par ordinateur tel que les robots.
D Veiller ร ce que tout lโรฉquipement de la zone de soudage soit com-
patible รฉlectromagnรฉtiquement.
D Pour rรฉduire la possibilitรฉ dโinterfรฉrence, maintenir les cรขbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller ร souder ร une distance de 100 mรจtres de tout รฉquipement
รฉlectronique sensible.
D Veiller ร ce que ce poste de soudage soit posรฉ et mis ร la terre
conformรฉment ร ce mode dโemploi.
D En cas dโinterfรฉrences aprรจs avoir pris les mesures prรฉcรฉdentes, il
incombe ร lโutilisateur de prendre des mesures supplรฉmentaires tel-
les que le dรฉplacement du poste, lโutilisation de cรขbles blindรฉs, lโuti-
lisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNรTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez ร dis-
tance.
D Les porteurs dโun stimulateur cardiaque doivent
dโabord consulter leur mรฉdecin avant de sโappro-
cher des opรฉrations de soudage ร lโarc, de gou-
geage ou de soudage par points.
OM-818 Page 8
1-4. Principales normes de sรฉcuritรฉ
Safety in Welding and Cutting, norme ANSI Z49.1, de lโAmerican Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de lโAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Rรจgles de sรฉcuritรฉ en soudage, coupage et procรฉdรฉs connexes, norme
CSA W117.2, de lโAssociation canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI Z87.1, de lโAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs รฉlectromagnรฉtiques
Donnรฉes sur le soudage รฉlectrique et sur les effets, pour lโorganisme,
des champs magnรฉtiques basse frรฉquence
Le courant de soudage, pendant son passage dans les cรขbles de sou-
dage, causera des champs รฉlectromagnรฉtiques. Il y a eu et il y a encore
un certain souci ร propos de tels champs. Cependant, aprรจs avoir ex-
aminรฉ plus de 500 รฉtudes qui ont รฉtรฉ faites pendant une pรฉriode de
recherche de 17 ans, un comitรฉ spรฉcial ruban bleu du National Re-
search Council a conclu: โLโaccumulation de preuves, suivant le
jugement du comitรฉ, nโa pas dรฉmontrรฉ que lโexposition aux champs
magnรฉtiques et champs รฉlectriques ร haute frรฉquence reprรฉsente un
risque ร la santรฉ humaineโ. Toutefois, des รฉtudes sont toujours en cours
et les preuves continuent ร รชtre examinรฉes. En attendant que les con-
clusions finales de la recherche soient รฉtablies, il vous serait
souhaitable de rรฉduire votre exposition aux champs รฉlectromagnรฉti-
ques pendant le soudage ou le coupage.
Afin de rรฉduire les champs รฉlectromagnรฉtiques dans lโenvironnement
de travail, respecter les consignes suivantes :
1 Garder les cรขbles ensembles en les torsadant ou en les
attachant avec du ruban adhรฉsif.
2 Mettre tous les cรขbles du cรดtรฉ opposรฉ de lโopรฉrateur.
3 Ne pas courber pas et ne pas entourer pas les cรขbles autour de
votre corps.
4 Garder le poste de soudage et les cรขbles le plus loin possible de
vous.
5 Relier la pince de masse le plus prรจs possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous รชtes dรฉclarรฉ apte par votre docteur, il est
alors recommandรฉ de respecter les consignes ciโdessus.
OM-818 Page 9
SECTION 2 โ INSTALLATION
2-1. Specifications For Racks Used With XMT 304 Models
Input Power Required Welding Power
Capacity
Input Power
To Rack
Required Welding Power
Source
4-Rack 6-Rack
230 Or 460 Volts AC;
60 Hz; Three Phase
XMT 304 Requiring 230 Or 460
Volt Input Power
1 โ 4 Welding Power Sources 1 โ 6 Welding Power Sources
460 Or 575 Volts AC;
60 Hz; Three Phase
XMT 304 Requiring 460 Or 575
Volt Input Power
1 โ 4 Welding Power Sources 1 โ 6 Welding Power Sources
2-2. Specifications For Racks Used With Invision Or Phoenix 456 Models
(Customer-Installed Only)
Input PowerInput Power
To Rack
Required Welding Power Source Capacity
460 Volts AC;
60 Hz; Three Phase
Phoenix 456 Or Invision 456 Models
Requiring 230/460 Volt Input Powerโ Operated On
460 Volt Input Power Only
1 โ 4 Welding Power Sources
575 Volts AC;
60 Hz; Three Phase
Phoenix 456 Or Invision 456
Requiring 575 Volt Input Power
1 โ 4 Welding Power Sources
2-3. Selecting A Location
loc_2 3/96 - ST-801 697
1 Lifting Eyes
Use lifting eye to move unit.
2 Lifting Forks
If using lifting forks, be sure forks
are fully inserted.
34-3/8 in
(873 mm)
59-3/8 in
(1508 mm)
43 in
(1092 mm)
Movement
Dimensions And Weight
256 lb (116 kg)
1
2
7 ft (2.1 m)
minimum length
7 ft (2.1 m)
minimum length
OM-818 Page 10
2-4. Installing Welding Power Source Onto Rack
Have only qualified persons make
this installation.
Y Turn Off welding power
sources before inspecting
or installing rack.
For XMT 304 Models
1 Welding Power Source
Position welding power source
onto rack shelf so threaded holes in
feet are over correct holes in shelf
on rack (see illustration). Welding
power source front panel should
face side of rack with isolated ter-
minal on base as shown.
2 Securing Bolts And Hardware
Install supplied bolts through rack
shelf into welding power source
feet and tighten.
For Phoenix and Invision Models
1 Welding Power Source
Position welding power source
onto rack shelf so holes in base of
welder align with correct holes in
shelf on rack (see illustration).
Welding power source front panel
should face side of rack with iso-
lated terminal on base as shown.
. The factory-supplied mounting
hardware is for XMT models
only. Do not attempt to use this
hardware when installing a
Phoenix or Invision onto rack.
Install user-supplied 1/4 in mount-
ing bolt through holes in welding
power source base and rack shelf
and tighten user-supplied hard-
ware to secure in place.
ST-801 192 / ST-801 696 / ST-801 698 / 802 260 / 802 537
1
2
For XMT And Phoenix/Invision Models For XMT Models Only
For Phoenix/Invision Models Only
Location of mounting holes
in bottom of base (both sides).
Mounting Hole Pat-
tern For
XMT Models
(Both Shelves)
Mounting Hole Pat-
tern For
Phoenix/Invision
Models
(Both Shelves)
Holes 1 And 4 Holes 5 And 6 Holes 7 And 10
Holes 2 And 5 Holes 6 And 9
Mounting
Shelves
OM-818 Page 11
2-5. Welding Power Source Input Power Connections
Y Disconnect input power to rack
before working on wiring for any
welding power source.
Have only qualified persons make this instal-
lation.
1 Control Box
Open access door on front of control box.
2 Strain Relief Connector
3 Welding Power Source Input Power
Cord
Each welding power source location on the
rack is numbered. The numbers on the con-
trol box access door refer to the similarly lo-
cated strain relief connectors and circuit
breakers inside the control box. Insert power
cord into strain relief with number matching
location of welding power source on rack.
4 Grounding Conductor โ Green Or
Green With Yellow Stripe(s)
5 Grounding Terminal
Install grounding conductor to grounding
terminal.
6 Input Conductors
7 Power Circuit Breaker Terminals
. When installing conductors from the
welding power source, torque the Power
circuit breaker terminals and grounding
terminal to 40 in-lbs (4.5 Nยทm).
Install input conductors from welding power
source to Power circuit breaker nearest entry
for input conductors.
Tighten strain relief connector. Close and se-
cure access door.
Ref. ST-801 703 / ST-801 699
Tools Needed:
1 2 3
6
4 57
1
Side View
OM-818 Page 12
2-6. Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 โ 60%
Duty Cycle
60 โ 100%
Duty Cycle
10 โ 100% Duty Cycle
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 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
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. S-0007-D
OM-818 Page 13
2-7. Common Work Connections
ST-801 700
Y Turn Off welding power sources by
placing Power circuit breakers in the
Off position before making any weld
output connections.
Y Do not connect welding output of dif-
ferent polarities to the same struc-
ture.
Y See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q
(addresses at beginning of manual).
Y Do not handle or come in contact with
two live electrodes at the same time.
Y ARCING can burn skin or damage
electrical equipment. Do not change
position of the welding cable connec-
tors while welding.
Y Be sure the connectors are secure in
receptacles before welding.
Y INADEQUATE WORK CABLE CON-
NECTIONS can cause serious dam-
age to input power service and create
a hazardous condition. Connect an
electrical cable of adequate size be-
tween the isolated terminal and the
workpiece whenever the isolated ter-
minal is used.
1 Positive (+) Weld Output Cables
Determine cable lengths and sizes accord-
ing to welding power source Ownerโs
Manual.
2 Isolated Terminal
3 Negative (โ) Weld Output Cables
Determine cable sizes according to welding
power source Ownerโs Manual. Cable must
reach from negative (โ) output receptacle to
isolated terminal.
4 Common Negative (โ) Weld Output
Cable
Cable must be able to carry combined weld
output of all welding power sources using
common work connections. Use Section 2-6
to select proper cable size.
5 Terminal Lugs
Use lugs of proper amperage capacity and
hole size for connecting to isolated terminal.
Isolated terminal is 1/2 in (12.7 mm) in
diameter.
For Electrode Negative, reverse cable con-
nections. Positive (+) weld output cables
connect to isolated terminal, negative (โ)
weld output cables go to electrode. Common
weld output cable is positive.
1
3
4
2
4
5
3
5
OM-818 Page 14
2-8. Paralleling Welding Power Sources For SMAW
ST-801 701
Y Turn Off welding power sources by
placing Power circuit breakers in the
Off position before making any weld
output connections.
Y Do not connect welding output of dif-
ferent polarities to the same
structure.
Y See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q
(addresses at beginning of manual).
Y Do not handle or come in contact with
two live electrodes at the same time.
Y UNDERSIZED WELDING CABLES
can cause fire. Use single cables of
adequate capacity to carry the total
combined amperage of the paralleled
welding power sources
Y ARCING can burn skin or damage
electrical equipment. Do not change
position of the welding cable connec-
tors while welding.
Y Be sure the connectors are secure in
receptacles before welding.
Y INADEQUATE WORK CABLE CON-
NECTIONS can cause serious dam-
age to input power service and create
a hazardous condition. Connect an
electrical cable of adequate size be-
tween the isolated terminal and the
workpiece whenever the isolated ter-
minal is used.
Set the Amperage/Voltage control on all par-
alleled welding power sources to the same
value. The isolated terminal may be used as
a common connection point if no other con-
nections are made to it.
The procedure shown is for Electrode Posi-
tive welding connections.
1 Weld Output Cables
Determine cable sizes according to welding
power source Ownerโs Manual. Cables must
reach cable connection point. Cables con-
nected together must be the same polarity.
2 Connection Point
Cover with proper insulating material after
making connections.
3 Terminal Lugs
Use lugs of proper amperage capacity and
hole size for connection.
4 Common Weld Output Cable
Cable must be able to carry combined weld
output of all welding power sources con-
nected in parallel. Use Section 2-6 to select
proper cable size.
For Electrode Negative, reverse cable con-
nections. Positive (+) weld output cables con-
nect to work, negative (โ) weld output cables
go to electrode.
3
4
Securely cover connection
with proper insulating
material.
1
1
4
1
4
2
OM-818 Page 15
2-9. Connecting Input Power To Rack
Have only qualified persons make
this installation.
Y Turn Off welding power
sources before inspecting
or installing rack.
1 Control Box
Open access door.
2 Line Disconnect Device Of
Proper Rating
3 Input Conductors
4 Grounding Conductor
Select size and length using Sec-
tion 2-10 or 2-11. Conductors must
be able to carry the combined am-
perage draw of all welding power
sources mounted on the rack. Con-
ductor insulation must comply with
national, state, and local electrical
codes.
5 Strain Relief Connector
Insert conductors through strain
relief.
6 Input Terminal Block
7 Line Terminals
8 Ground Terminal
Connect grounding conductor to
ground terminal first. Then connect
input conductors to line terminals.
Close control box access door.
Install grounding conductor and in-
put conductors in conduit or equiv-
alent to deenergized line discon-
nect device.
Connect grounding conductor first,
then line input conductors.
Be sure grounding conductor goes
to an earth ground.
9 Overcurrent Protection
Select type and size using Section
2-10 or 2-11. Install into deen-
ergized line disconnect device
(fused disconnect switch shown).
ST-801 702 / Ref. ST-801 703
1
6
8
4
5
2
37
3
4
9
OM-818 Page 16
2-10. Electrical Service Guide For XMT 304 4-Racks
Input Voltage
230 460 575
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
200 110 90
Min Input Conductor Size In AWG/Kcmil
2 6 8
Max Recommended Input Conductor Length In Feet (Meters)
210 (64) 301 (92) 300 (91)
Min Grounding Conductor Size In AWG/Kcmil
6 6 8
Reference: 1996 National Electrical Code (NEC). S-0092J
2-11. Electrical Service Guide For XMT 304 6-Racks
Input Voltage
230 460 575
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
300 175 125
Min Input Conductor Size In AWG/Kcmil
1/0 2 4
Max Recommended Input Conductor Length In Feet (Meters)
215 (66) 451 (137) 467 (142)
Min Grounding Conductor Size In AWG/Kcmil
4 6 6
Reference: 1996 National Electrical Code (NEC). S-0092J
2-12. Electrical Service Guide For Phoenix/Invision 456 Racks (Customer-Installed Only)
Input Voltage*
460 575
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
200 175
Min Input Conductor Size In AWG/Kcmil
2 2
Max Recommended Input Conductor Length In Feet (Meters)
210 (64) 451 (137)
Min Grounding Conductor Size In AWG/Kcmil
6 8
* Due to current demands, a rack containing Phoenix/Invisions requiring 230/460 volt input power must be connected to 460 volt input power
only.
Reference: 1996 National Electrical Code (NEC). S-0092J
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Miller LA106279 Owner's manual
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- Owner's manual
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