Miller AEROWAVE CE Owner's manual

Miller
Brand
Miller
Model
AEROWAVE CE
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
August1996
Effective
With
Form:
Serial
No.
OM-183
KG194818
17~7
OWNERS
MANUAL
CE
Ae
rowave
fi
CC
AC/DC
Welding
Power~Source
For
GTAW
And
SMAW
Welding
'
1996
MILLER
Electric
Mfg.
Co.
cover_om
4/9~
ST-800
311-B
Rated
Welding
Output
Amperes
Input
at
AC
Balanced
Rated
Load
Output;
50
Hz,
Three-Phase
KVA
.
KW
Amperage
Range
Max
OCV
380
V
415
V
Three-Phase:
NEMA
Class
I
(60)
300
Amperes,
32
Volts
AC/DC,
60%
Duty
Cycle
23
21
14.8
14
1375
A
90
PRINTED
IN
USA
LIMITED
WARRANTY
Subject
to
the
terms
end
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
wsrrsnts
to
its
original
retail
purchaser
thst
new
MILLER
equipment
sold
sfter
the
effective
dste
of
this
limited
werranty
is
free
of
de
fects
in
materiel
end
workmsnship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRAN11ES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
wsrrsnty
periods
listed
below,
MILLER
will
repsir
or
repisce
any
wsr
ranted
pens
or
components
thst
fell
due
to
such
defects
In
msterisl
orworkrnenship.
MILLER
must
be
notified
in
writing
within
thIrty
(30)
days
of
such
defect
or
tsiiure,
at
which
time
MILLER
will
provide
Instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shell
honor
warranty
claims
on
warranted
equipment
iisted
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
wsrranty
time
periods
start
on
the
date
that
the
equipment
wss
delivered
to
the
originsi
retsil
purchaser,
or
one
year
after
the
equipment
Is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
Is
sent
to
err
internstionsi
distributor.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
pens
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperty
operated
or
misused
based
upon
Industry
standards,
or
equipment
which
has
not
had
reasonable
and
necesssry
msintensnce,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIALI1NDUSTR1AL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
ThE
USE
AND
MAINTENANCE
OF
WELDING
EOU1PMENt
tn
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusIve
remedies
shell
be,
at
MILLERS
option:
(1)
repalr
or
(2)
replacement;
or;
where
authorized
In
writing
by
MILLER
in
approprista
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chsse
price
(teas
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
end
expense.
MILLERS
option
of
repair
or
replacement
wilt
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
ROB.
ate
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensatIon
or
reimburse
ment
for
transportatIon
costs
of
any
kind
will
be
allowed.
TO
ThE
EXTENT
PERMITrED
BY
LAW,
THE
REMEDIES
PRDV1DED
HEREIN
ARE ThE
SOLEAND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALLMILLER
BE
UABLE
FOR
DIRECt
INDIRECt
SPECIAL,
INCIDENTAL
OR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACt
TORT
OR
ANY
OTHER
LEGAL
ThEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTA11ON
AS
TO
PERFORMANCE,
AND ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OThER
LEGAL
ThEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPUCATION,
OPERATiON
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY
AND
ALL
EOU1PMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
statas
in
the
U.S.A.
do
not
allow
limitations
of
how
long
en
implied
warranty
lasts,
or
the
esciusion
of
incidental,
indirect,
special
or
consequential
dsmsges,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
end
other
rights
may
be
available,
but
may
vary
from
state
to state.
in
Csnsds,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
end
to
the
extent
that
they
may
not
be
waived,
the
limitations
end
exclusIons
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
end
other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
contact
your
distribUtor
For
additional
Information,
such
as
Tochnical
Manuals
(Service
And
Parts)
Engino
Manuals
Circuit
And
Wiring
Diagrams
To
file
a
claim
for
loss
or
damage
during
shipment,
.
contact
the
doliVering
canior
For
assistance
in
filing
or
sealing
claims,
contact
your
distributor
and/or
oquipmont
manufacturers
Transportation
Dopartmont
pc~~~
~h]
Miller
Electric
Mfg.
Co.
CALL:
414-7354505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Process
Handbooks
Users
Guides
Distributor
Directories
.
o~
=
.
WRITE:
Miller
Electric
Mfg.
Co.
contact
your
distributor
P.O.
BOX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
I-.
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
wsrrenties
end
is
exclusive
with
no
other
guarantees
or
warranties
expreased
or
implied.
5.
6
Months
Batteries
6.
90
Days
Parts
and
Lsbor
-
MIG
GunsfflG
Torches
*
APt
ZIPCUT
&
PLAZCUT
Model
Piasms
Cutting
Torches
*
Remote
Controls
-
Acceasory
Kits
*
Replacement
Pans
MILLERS
True
Bluefi
LimIted
Warranty
shall
not
apply
to:
1.
Items
fumished
by
MILLER,
but
menufsctured
by
others,
such
as
engines
or
trsde
scceasories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
.J
ii
(7)
S
Yesm
Parts
-3
Years
Lsbor
*
Original
main
power
rectifiers
-
Invertere
(Input
and
Output
rectifiers
only)
2.
3YesrePertssndLsbor
.
~
-
Trsnsfomier/Rectlfier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
end
Automatic
Wire
Feeders
*
Inverter
Power
Supplies
intettlig
-
Robots
(1
yesr
labor)
3.
2
Years
Pens
and
Labor
-
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
msnufscturer.)
-
Air
Compreasors
4.
1
Year
Pans
and
Labor
-
Motor
Driven
Guns
*
Process
Controllers
*
IHPS
Power
Sources
Water
coolant
Systems
HF
Units
Grids
-
Spot
Welders
Load
Banks
*
SDX
Transformers
Miller
Cyciomatic
Equipment
-
Running
Gear/Trailers
*
Plasma
Cutting
Torches
(except
APt
Z1PcuT
&
PLAZCuT
Models)
*
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
era
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
Installed
in,
or
fore
minimum
of
one
year
whichever
is
greater.)
miller
wan
3/96
Declaration
of
Conformity
For
European
Community
(CE)
Products
NOTE
~
This
in
formation
is
provided
for
units
with
CE
certification
(see
rating
label
on
unit.)
Manufacturers
Name:
Miller
Electric
Mfg.
Co.
Manufacturer~s
Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares
that
the
product
Ae
rowave
fi
con
forms
to
the
following
Directives
and
Standards:
Directives
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Electromagnetic
Capabillty
Directives:
89/336,
92131/EEC
Standards
Electromagnetic
compatibility
(EMC)
Product
standard
for
arc
welding
equipment:
EN50199:
August
1995
European
Contact
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via
Privata
Iseo
20098
San
Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_coni
10/95
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
2
1-4.
Principal
Safety
Standards
3
1-5.
EMF
Information
3
SECTION
2-
DEFINITIONS
4
2-1.
Warning
Label
Definitions
4
2-2.
Rating
Label
For
CE
Products
5
2-3.
Symbols
And
Definitions
6
SECTION
3-INSTALLATION
7
3-1.
Dimensions
And
Weights
7
3-2.
Selecting
A
Location
7
3-3.
115
VAC
Receptacle,
Circuit
Breaker,
And
Shielding
Gas
Connections
8
3-4.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
8
3-5.
Remote
14
Receptacle
Information
9
3-6.
Electrical
Service
Guide
9
3-7.
Placing
Jumper
Links
10
3-8.
Connecting
Input
Power
11
SECTION
4OPERATION
12
4-1.
Controls
12
4-2.
Polarity
Switch
And
Pilot
Lights
12
4-3.
Mode
Switch
13
4-4.
Amperage/Preset
Meter
And
Voltmeter
13
4-5.
Output
Switch
And
Pilot
Light
13
4-6.
Amperage
Adjustment
Controls
14
4-7.
Examples
Of
Combination
Remote
Amperage
Control
15
4-8.
AC
Balance
Control
16
4-9.
AC
Frequency
Controls
16
4-10.
Postflow
Time
Control
17
4-11.
Start
Switch
17
4-12.
Power
Switch
17
4-13.
Optional
Controls
18
4-14.
GTAW
Trigger
Hold
Switch
(Optional)
18
4-15.
Spot
Time
Controls
(Optional)
19
4-16.
Preflow
Time
Controls
(Optional)
19
4-17.
Initial
Sequence
Controls
(Optional)
19
4-18.
Pulser
Controls
(Optional)
20
4-19.
Final
Sequence
Controls
(Optional)
20
4-20.
Pulsed
Weld
Waveforms
21
4-21.
Duty
Cycle
And
Overheating
22
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
22
5-1.
Routine
Maintenance
22
5-2.
Overload
Protection
And
Adjusting
Spark
Gap
23
5-3.
Troubleshooting
24
SECTION
6-
ELECTRICAL
DIAGRAM
26
SECTION
7
HIGH
FREQUENCY
(HF)
28
7-1.
Welding
Processes
Using
HF
28
7-2.
Sources
Of
HF
Radiation
From
Incorrect
Installation
28
7-3.
Correct
Installation
29
SECTION
8
PARTS
LIST
30
OM-183
1738196
1-1.
Symbol
Usage
~H~id
1-2.
Arc
Welding
Hazards
a
WARNING
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.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
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).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
bum
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
_______
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
I
ear
plugs
or
ear
muffs
if
noise
level
is
high
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
yourface
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
3.
Wear
approved
safety
glasses
with
side
shields.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
6.
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.
7.
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.
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
8afety_soml
4/95
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
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.
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.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
NOISE
OM-183
173
Page
1
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.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
arty
cylinder.
6.
Never
weld
on a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
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.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
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).
8.
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.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
oft
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
near
combustible
surfaces.
1.
Do
not
locate
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
HOT
PARTS
can
cause
severe
burns.
1.
Do
not
touch
hot
parts
bare
handed.
2.
Allow
cooling
period
before
working
on
gun
or
torch.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch
points
such
as
drive
rolls.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
WELDING
WIRE
can
cause
puncture
wounds.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HIGH-FREQUENCY
RADIATION
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
checked
and
maintained.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
1.
2.
3.
~Ił~
-jt
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
OM-183
173
Page
2
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Follow
rated
duty
cycle.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
1.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
,~
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
1-4.
Principal
Safety
Standards
w
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shut
oft
shielding
gas
supply
when
not
in
use.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.
1,
from
Safe
Hand/mg
of
Compressed
Gases
in
cylinders,
CGA
Pamphlet
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
P-i
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Highway,
Suite
501,
Ariington,
VA
22202.
Code
for
Safety
in
We/ding
and
Cutting,
CSA
Standard
W117.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Recommended
Safe
Practices
for
the
Preparation
for
We/ding
and
Cutting
of
Containers
.~iat
Have
Held
Hazardous
Substances,
American
Welding
Socoty
Standard
AWS
F4.1,
from
American
Welding
Society,
550
l\
V.
LeJeune
Rd,
Miami,
FL
33126
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
51
B,
from
National
Electrical
Coc
NFPA
Standard
70,
from
National
Fire
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
Protection
Association,
~tterymarch
Park,
Quincy,
MA
02269.
MA
02269.
1-5.
EMF
Info
~ation
Considerations
AboL
elding
And
The
Effects
Of
Low
Frequency
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnet
~lds
procedures:
The
following
is
a
q~
~
from
the
General
Conclusions
Section
of
the
U.S.
Congress.
ce
of
Technology
Assessment,
Biological
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Effects
of
Power
.uency
Electric
&
Magnetic
Fields
Background
Paper,
1TA-BP-E-53
(Washington,
DC:
U.S.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
Government
Printing
C~ce,
May
1989):
.
. .
there
is
now
a
very
3.
Do
not
coil
or
drape
cables
around
the
body.
large
volume
of
scientific
findings
based
on
experiments
at
the
cellularlevel
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
practical.
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
About
Pacemakers:
.
riskortoofferclearscience-basedadviceonstrategiestominimize
The
above
procedures
are
also
recommended
for
pacemaker
or
avoid
potential
risks.
wearers.
Consult
your
doctor
for
complete
information.
OM-183
173
Page
3
SECTION
2-
DEFINITIONS
1
Electric
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Wear
dry
insulating
gloves.
Do
not
touch
electrode
with
bare
hand.
Do
not
wear
wet
or
damaged
gloves.
1.2
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
1.3
Disconnect
input
plug
or
power
before
working
on
machine.
2
Breathing
welding
fumes
can
be
hazardous
to
your
health.
2.1
Keep
your
head
out
of
the
fumes.
2.2
Use
forced
ventilation
or
local
exhaust
to
remove
the
fumes.
2.3
Use
ventilating
fan
to
remove
fumes.
3
Welding
sparks
can
cause
explosion
or
fire.
3.1
Keep
flammables
away
from
welding.
Dont
weld
near
flammables.
3.2
Welding
sparks
can
cause
fires.
Have
a
fire
extinguisher
nearby
and
have
a
watch
person
ready
to
use
it.
3.3
Do
not
weld
on
drums
or
any
closed
containers.
4
Arc
rays
can
bum
eyes
and
injure
skin.
4.1
Wear
hat
and
safety
glasses.
Use
ear
protection
and
button
shirt
collar.
Use
welding
helmet
with
correct
shade
of
filter.
Wear
complete
body
protection.
5
Become
trained
and
read
the
instructions
before
working
on
the
machine
or
welding.
6
Do
not
remove
or
paint
over
(cover)
the
label.
2-1.
Warning
Label
Definitions
Waming!
Watch
Out!
There
are
symbols.
possible
hazards
as
shown
by
the
OM-183
173
Page
4
2-2.
Rating
Label
For
CE
Products
EN
60974-1
Ui
380V
I
umax
32A
j
1len
4A
U2
415V
I
imax
29A
I
left
3.7A
0
=
4.0
Kvar
OM-183
173
Page
5
2-3.
Symbols
And
Defirntions
A
Amperes
0
PanelLocal
Q~$
Gas
Tungsten
Arc
Welding
(GTAW)
/~
Shielded
Metal
Arc
Welding
(SMAW)
~%f
Volts
f
Frequency
V
Itfi
Over
Voltage
~~
t
Spot
Timer
Output
o o
Circuit
Breaker
,AJ
Remote
Touch
Start
(GTAW)
Protective
Earth
(Ground)
Alternating
Current
~\
High
Frequency
-
Start
Input
t2
Postflow
Timer
ti
Preflow
Timer
Q
Kvar
F~~
i:
High
Frequency
S
Seconds
Gas
Input
(~j~j~i
Gas
Output
Gas
(Supply)
On
~p
Off
Thickness
Gauge
Direct
Current
F:;iL::j
Balance
Control
9
~%
Maximum
Cleaning
-v-
Maximum
Penetration
+
A
.I,
.~..
~
Electrode
Positive
/\

Electrode
Negative
...4~.....
Work
.4~\
~
Electrode
3~\,
Three-Phase
J1J1L
Pulse
Frequency
Pulse
Percent
On
Time
J1J]~
Pulse
Background
Amperage
~j\
Start
Time
~I\
Start
Amperage
j~_~
Final
Slope
O/~
Percent
U
0
Rated
No
Load
Voltage
(Average)
U
1
Pnmar~,
Voltage
U2
Conventional
Load
Voltage
IJ
~
Line
Connection
I~
PrimaryCurrent
12
Rated
Welding
Current
X
DutyCycle
~-GD-f~~
Three-Phase
CombinedAC/DC
Power
Source
I
P
Degree
Of
Protection
left
Maximum
Effective
Supply
Current
1
max
Rated
Maximum
Supply
Current
h1!T~
~
Spark
Gap
()
Increase/Decrease
Of
Quantity
At
Final
Sequence
t
Two-Step
Trigger
Operation
(GTAW)
J~j
Four-Step
Trigger
Operation
(GTAW)
Initial
Sequence
Final
Amperage
/\~
Final
Time
~J\
Initial
Slope
Press
And
Hold
Li
Trigger
Hold
(GTAW)
j~fi
High
Temperature
OM-183
173
Page
6
SECTION
3INSTALLATION
Height*
35-1/2
in
(910
mm)
Width
24
in
(615
mm)
Depth
22-3/4
in
(583
mm)
*With
lifting
eye
down
Weight
3-1.
Dimensions
And
Weights
c~
Dimensions
B
dim_i
3/96
-
ST-800
402/ST-il
7
264-C
3-2.
Seecting
A
Location
351
lb
(159
kg)
OM-183
173
Page
7
3-3.
115
VAC
Receptacle,
Circuit
Breaker,
And
Shielding
Gas
Connections
1
115
V
15
A
AC
Receptacle
RC2
2
Circuit
Breaker
CB1
Receptacle
is
protected
from
over
load
by
CB1.
Press
button
to
reset
breaker.
3
Gas
Fittings
Fittings
have
5/8-18
right-hand
threads.
4
Cylinder
Valve
Open
valve
slightly
so
gas
flow
blows
dirt
from
valve.
Close
valve.
5
Regulator/Flowmeter
6
Flow
Adjust
Typical
flow
rate
is
15
cfh
(cubic
feet
per
hour).
~
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
~f
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
t~r!J
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.
Weld
Output
Terminals
Welding
Amperes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
100
ft
(30
m)
Or
Less
150ft
I
(45
m)
200ft
(60
m)
250ft
(70
m)
300ft
350ft
(90_m~j(105_m)
400ft
(120
m)
1060%
Duty
Cycle
60100%
Duty
Cycle
10
100%
Duty
Cycle
irf~~TiEEEiT
0
7~
~
,k
100
4
4
4
3
2
1
1/0
1/0
150
200
3
3
3
2
2
1
1
1/0
1/0
2/0
2/0
3/0
3/0
4/0
3/0
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
Ref.
ST-800
312-A
500
2/0
3/0 4/0
2-2/0
2-3/0
2-4/0 3-3/0
3-3/0
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
2
3
hoses
under
bar.
Tools
Needed:
~
5/8,1-1/8in
3-4.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
OM-183
173
Page
8
3-5.
Remote
14
Receptacle
Information
3-6.
Electrical
Service
Guide
A
24
volts
ac.
f~
~
OWVUT
(c0NTPCTOR)
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
Three-Phase
Input
Voltage
380
415
Input
Amperes
At
Rated
Output
23
21
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
35
30
Mm
Input
Conductor
Size
In
AWG/Kcmil
12
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
132(40)
102
(31)
Mm
Grounding
Conductor
Size
In
AWGIKcmiI
12
14
Reference:
1996
National
Electrical
Code
(NEC).
S-0092J
Socket*
Information
C
Command
reference;
0
to
+10
volts
dc
output
to
remote
control.
A
AMPERAGE
D
Remote
control
circuit
common.
The
remaining
sockets
are
not
used.
Ref.
ST-800
312-A
E
K
0
to
+10
volts
dc
input
command
signal
from
remote
control.
Circuit
Common
OM-183
173
Page
9
3-7.
Placing
Jumper
Links
2
Tools
Needed:
c::::::3:==n
3/8
in
Check
input
voltage
available
at
site.
Ref.
ST-BOO
314
1
Primary
Terminal
Board
2
Jumper
Link
Label
Move
jumper
links
to
match
input
voltage,
and
label
on
unit.
Proceed
to
Section
3-8.
OM-183
173
Page
10
3-8.
Connecting
Input
Power
1
Input
And
Grounding
Conductors
See
Section
3-6.
2
Line
Disconnect
Device
See
Section
3-6.
Reinstall
rear
cover.
Tools
Needed:
3/8,
1/2,
7/16
in
input3
3/96
-
Ret.
ST-601
654
OM-183
173
Page
11
4-1.
Controls
SECTION
4-
OPERATION
A
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
dan
ger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process,
and
then
use
a
remote
output
control.
1
Polarity
Switch
Use
switch
to
select
weld
output.
2
Electrode
Positive
Pilot
Light
3
Electrode
Negative
Pilot
Light
Both
lights
go
on
when
switch
is
in
AC
position.
1
2
2
\
3
\\
4
5
\
3
6
\
7
I
n
4
8
I
Light
9
I
e
10
/
5
/
11
/
/
/
6
/
Mode
Switch
(See
Section
4-3)
Amperage
Switch
(See
Section
4-6)
Output
Switch
And
(See
Section
4-5)
Start
Switch
(See
Section
4-11)
Polarity
Switch
And
Lights
(See
Section
4-2)
Amperage/Preset
Meter
(See
Section
4-4)
Voltmeter
(See
Section
4-4)
Amperage
Adjustment
Controls
(See
Section
4-6)
AC
Frequency
Controls
(See
Section
4-9)
10
High
Temperature
Shutdown
Light
I
7
(1)
p/-~
8
0
_
12
9
13
11
Over
Voltage
Shutdown
Light
See
Section
5-2)
12
Postt
low
Time
Control
(See
Section
4-10)
13
AC
Balance
Controls
(See
Section
4-8)
14
Power
On/Off
Switch
(See
Section
4-12)
14
A
Wear
approved
ear
muffs
or
ear
plugs
if
noise
exposure
exceeds
OSHA
limits.
4-2.
Polarity
Switch
And
Pilot
Lights
ST-800
312-A
+1-
Ret.
ST-i
69
496-A
OM-183
173
Page
12
4-3.
Mode
Switch
4-4.
Amperage/Preset
Meter
And
Voltmeter
4-5.
Output
Switch
And
Pilot
Light
A
Weld
output
terminals
are
energized
when
switch
is
On
and
power
is
On.
Do
not
touch
torch
or
electrode
and
work
clamp
at
the
same
time.
1
Output
Switch
2
Pilot
Light
Use
switch
to
select
way
of
control
ling
unit
output.
For
weld
output,
place
switch
in
On
position.
For
remote
output
control,
place
switch
In
Remote
14
position
(see
Section
3-5).
Pilot
light
stays
on
continuously
in
On
position,
but
only
when
contac
tor
is
energized
in
Remote
14
position.
1
1
Mode
Switch
Use
switch
to
select
SMAW
or
either
GTAW
welding
process.
Selecting
either
GTAW
position
en
ables
the
Start
switch
and
gas
valve;
both
are
disabled
when
the
Q
SMAW
position
is
selected.
GTAW
Trigger
Hold
functions
as
follows:
Press
torch
switch
to
start
arc.
Switch
can
be
released
and
arc
re
mains
on.
Press
switch
to
stop
arc.
A
V
1
Amperage/Preset
Meter
Use
meter
to
preset
amperage,
ac
frequency,
and
ac
balance.
Meter
displays
average
weld
amperage
output
of
unit
to
nearest
ampere
when
welding.
2
Voltmeter
Voltmeter
displays
average
volt
age
(to
the
nearest
0.1
V)
at
the
weld
output
terminals.
2
I
1
OM-183
173
Page
13
4-6.
Amperage
Adjustment
Controls
1
Amperage
Control
Switch
Use
switch
to
select
way
of
control
ling
amperage
adjustment.
For
front
panel
control,
place
switch
in
Panel
position.
For
remote
control,
place
switch
in
Remote
14
position.
2
Electrode
Positive
Amperage
Adjustment
Control
And
Pushbutton
Set
Polarity
switch
to
AC,
press
pushbutton
and
use
control
and
Amperage/Preset
meter
to
adjust
weld
amperage
for
positive
half
of
ac
square
wave.
When
Polarity
switch
is
in
Elec
trode
Positive
position,
pushbutton
does
not
need
to
be
pressed
to
ad
just
control.
3
Electrode
Negative
Amperage
Adjustment
Control
And
Pushbutton
Set
Polarity
switch
to
AC,
press
pushbutton
and
use
control
and
Amperage/Preset
meter
to
adjust
weld
amperage
for
negative
half
of
ac
square
wave.
When
Polarity
switch
is
in
Elec
trode
Negative
position,
pushbut
ton
does
not
need
to
be
pressed
to
adjust
control.
The
controls
require
3
tums
to
go
from
minimum
to
maximum,
and
may
be
adjusted
while
welding.
Set
Electrode
Positive
Amperage
Level
)
Set
Electrode
Negative
Amperage
Level
+150
A
Electrode
Positve
Output
=
250
A
Electrode
Negative
Ref.
ST-169
496-A/
Ref.
S-0865
0
A
3
If
Polarity
switch
is
set
incorrectly,
the
Amperage/Preset
meter
goes
blank
when
the
pushbutton
is
pressed.
Example:
Setting
Amperage
For
AC
Output:
15
~ffl
AMPERAGE/PRESET
~soffl
AMPERAGE/PRESET
A~
OM-183
173
Page
14
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Miller AEROWAVE CE Owner's manual

Miller
Brand
Miller
Model
AEROWAVE CE
Category
Welding System
Type
Owner's manual
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