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Horizon Fitness ELITE 2.0B Home Gym User Manual

Contents

1. 1 A 201155 Bushing Strain Relief 450 709 Id X1 068 Mtg Hole 1 pov 207253 akse Plug GAS PI iau iro iara de Dea eR ei nana LER o RH d 1 1 PNE TC uns 198245 Nut Conduit 750 Npt Pld 1 388 Od X 150 Thk 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2233 Page 43 Description 7 Hardware is common and not available unless listed Figure 11 4 Magnetics Assembly w Components Item Dia Part No Mkgs No 202 398 H Quantity Figure 11 4 Magnetics Assembly w Components Figure 11 1 Item 3 pM 195649 Panel Plenum is E EE ee 1 oos FM1 230808 Fan Muffin 24vdc 4200 RPM 140 CFM 4 125 MTG HOLES 1 E oS CR1 198549 Relay Encl 24vdc Spst 35a 300vac 4pin Flange Mig 1 Ste 189790 55 NAUEN QUIDIU sang re Se Se 1 EEE 2 aa 210599 ze OOM IMGUCION OL ugue et tas ene oto eae d te oet e Lu edad 1 7 6 un L3 ims 206020 4x Gol Inductor TAT 2 228 dem ad Hire cie 1 1 RN MA gen 212268 Xfmr HF Litz Litz w Boost 1 A A 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide
2. 1 19 rd A 195663 sa SAP Shoulder 6 EE as o da dd a di d 1 PLE 189782 Insulator Interconnect Board 1 Doy ct Gris 213974 1 50 aDacllOL ASSI duen id see RAR eee des 1 lors E 189778 5 Plug WiEeads VID orsi anp eia mdan aoa Saal EI EUER Pains we 1 TO 2o se 202400 Plug W Leads Boost Relay 1 19 DET 189779 GC able Per VV PIUGOS us ae Set Uh re dee dro er oen t 1 PISA RC ee 189784 Insulator Wrapper 2 PO ae ia 198147 Label Side Maxstar 200 2 Ly QOEM 199478 Label Miller 6 000 X 2 500 Horizontal 2 Duc c c ET 203990 Label Warning General Precautionary Non CE Models 2 20 uti dope pagos o su 179310 Label Warning General Precautionary CE Models 2 es ne 185835 Label Warning Electric Shock Exploding Parts Non CE Models 1 DO voulais EL 185836 Label Warning Electric Shock Exploding Parts CE Models 1 DD HUE 208998 Label Rating Card Code 122 Serial amp Stock Number 1 S MT re do 182826 Label Warning Electric Shock Power Cord 1 O qued adi tate p e tas 207310 Core Toroidal CE Models Only 1 Sd asisten iacet ee 215002 24 Clips OUDON PO MG ts dos
3. 3 4 Symbols And Definitions A Amperes E Shielded Metal Arc Welding SMAW Gas Tungsten Arc Welding GTAW x A High Temperature vO We pup Se Tooo Percent AN Arc Force DIG Remote 18 gs Q mo umm p em S su On O Off Positive Negative X Duty Cycle Direct Current T Line Connection U 9 ica d 2960 U Primary Voltage D Degree Of Rated Maximum Maximum Effective Protection Supply Current Supply Current 1 imax pply 1eff pply U Rated No Load H Hene m Increase Decrease 0 Voltage Average Z Shock Hazard Of Quantity gt Output Adjust OM 2233 Page 11 SECTION 4 INSTALLATION 4 1 Specifications Welding Max Amperes Input At Rated Output 50 60Hz Input Power Rated Output Amperage Open Circuit KVA KW Range Voltage 115 230 400 460 Three Phase 150A Q 26 VDC 80V 154 74 6 4 52 50 Stick Process 6096 Duty Cycle 7 9 144 o 0 16 0 24 0 25 0 06 0 03 Three Phase 175 A 17 VDC ann 80 10 5 6 0 5 2 4 2 4 0 TIG Process 60 Duty Cycle 7 9 144 0 16 0 24 0 25 0 06 0 03 Three Phase 200 A 28 VDC NEN 80V 18 4 10 3 8 9 7 3 7 0 Stick Process 30 Duty Cycle g 9 14 0 16 0 24 0 25 0 06 0 03 Three Phase 200 A 18 VDC E 80 12 7 7 2 6 2 5 1 4 9 TIG Process 40 Duty Cycle 9 144 0 16 0 24 0 25 0 06 0 03 Single Phase 150A 26 VDC 7 80V 21 7 10 6 50 50
4. 2 1 nie ae S 196512 Bracket Inductor Mounting 2 VE AA tene 196514 Gasket Inductor Mounting 2 OM 2233 Page 44 Item Dia Part No Mkgs No Description Quantit Figure 11 4 Magnetics Assembly w Components Figure 11 1 Item 3 Continued E cesses NO NE 213208 Connector Faston Male 1 4 Ring W 75deg Bend 1 Ol is 057357 Bushing Snap in Nyl 937 Id X 1 125 Mtg Hole 2 ODA usos eee sun 182737 Screw 010 32x2 00 Rnd Hd slt Brs Pin 4 COS care 229323 Nut 010 32 31hex 13h Stl Pld Sem Cone Wshr 38d 4 OT dnas 136343 Screw K50x 20 Pan Hd phl Stl Pld Pt Thread Forming 2 CARS xd udine ets 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 2 Old as ure MERE 010381 Connector Rectifier 1 BIT ia sis 170647 Bushing Snap in nyl 1 312 ID X 1 500 Mtg Hole 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2233 Page 45 7 Hardware is common and not available unless listed 199 494 F Figure 11 5 Windtunnel w Components Item Dia Part No Mkgs No Description Quantit Figure 11 5 Win
5. 2 EE 185718 s O Ring 0 989 ID X 0 070 Wall 344533454648 his Medias anni tes 2 VO rss oct ee Re ated 186228 O Ring 0 739 ID X 0 070 Wall 2 LR eatin 202326 Recpt w leads and plug 14 pin 1 400 54004 POS sanis 217272 Circuit Card Assy Front Panel Interface W Program 1 400 PG MM 213922 Circuit Card Assy Front Panel Interface W Program 1 400 PC3 231249 Circuit Card Assy Front Panel Interface W Program CE ROHS 1 OR eco dades idae 231383 Washer Tooth 377 ID X 0 507 OD X 022T STL PLD INT 375 3 BOS diet chiens 178548 Terminal Connector Friction cee II 1 For models with stock number 907036 or 907037 For models with stock number 907355 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2233 Page 42 7 Hardware is common and not available unless listed 600 202 397 E 2 Figure 11 3 Panel Rear w Components Item Dia Part No Mkgs No Description Quantit Figure 11 3 Panel Rear w Components Figure 11 1 Item 2 NERONE HOPES 194242 se panel EROS uoc tue Tu Ii dL MEA ave 1 Da TU o aie 206053 Panel Rear Lower uduuded aude 2 pu mrt oe eu eB aed RAP Rte 1 G aa eee PRETIUM 195646 Panel Rear Upper
6. Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 2233 Page 39 SECTION 11 PARTS LIST 7 Hardware is common and not available unless listed 803 107 E Figure 11 1 Main Assembly OM 2233 Page 40 Item Dia Part No MKkgs No Description Quantit Figure 11 1 Main Assembly l as discedat cr Fig 2 2 54 Panel Front WOMPNL Een ete tdo aes vU o tiens 1 Dy ebat nn Fig11 3 Panel Rear W Cmpnt 1 li TEN Fig11 4 Magnetics Subassembly 1 A PN Fig11 5 Windtunnel W Components 1 oput ee FOTZ 42 BOONE ee DST Ae ee ere eum NR EA EE 1 Diana SE aa 128756 Switch Tgl 3pst 40a 600vac Scr Term Wide Tgl 1 o EROR CINE PM1 204821 Kit Input Pre Regulator Inverter 1 Success PI E 049611 Tubing Cop 540 Od X 123 Wall X 687 1 TOR mes 196727 Cable Power 10 Ft 12ga 4c Blk Red Wht Grnyel 1 lle sa A o ak cda ei iaces vale itch Ne Me DEN MS DL nds 1 rad sus 206108 Handle Rubberized Carrying
7. 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 dose Declares that the product M axsta r 200 ST R conforms to the following Directives and Standards European Contact Signature Directives Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Electromagnetic Capability Directives 89 336 92 31 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 December 1996 Draft revision Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1 1992 Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 dec stat 6 05 Notes SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage r Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols 7 Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbo
8. Part No Mkgs No Description Quantit Figure 11 7 Base Assembly Figure 11 1 Item 5 Der ee 195694 NN BOISE Hansd ti 1 Parese jura dende fuger 019663 Mount Norn 15 160dx3 8rec 3 16x3 8 4 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2233 Page 48 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also 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 7 Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN
9. Selecting Tungsten Electrode arv a v e DC bata e wen eae oe C e a de 28 8 2 Safety Information About Tungsten 28 8 3 Preparing Tungsten For AC Or DC Electrode Negative DCEN Welding 29 SECTION 9 GUIDELINES FOR TIG WELDING GTAW ooocooocooc III 30 9 1 Positioning The TOGN x uus oec ce ld serer week etse eda redet neve a eed 30 9 2 Torch Movement During Welding 2 31 9 3 Positioning Torch Tungsten For Various Weld Joints 1 32 TABLE OF CONTENTS SECTION 10 STICK WELDING SMAW GUIDELINES 4ssssssssssss 33 10 1 Stick Welding Procedure eae a ee eae een CE UC en ab CR 33 10 2 Electrode and Amperage Selection Chart 282 34 10 3 Striking an Arc Scratch Start Technique 0 ccc teen eens 34 10 4 Striking an Arc Tapping Technique 34 10 5 Positioning Electrode Folder arr ti ds ane bek bee bette Ba Ms ete dase erm A 35 10 6 Poor Weld Bead Characteristics 80 35 10 7 Good Weld Bead Characteristics 280 35 10 8 Conditions That Affect Weld Bead Shape 36 10 9 Electrode Movement Durin
10. Stick Process 60 Duty Cycle i 9 144 0 23 29 0 05 0 02 Single Phase 175 A 17 VDC ds 80 17 4 8 5 4 0 4 0 TIG Process 60 Duty Cycle y 9 144 0 23 y 25 0 05 0 02 Single Phase 125A 25 VDC 7 80V 34 1 40 38 Stick Process 50 Duty Cycle 7 9 144 0 42 7 i 0 05 0 03 Single Phase 150 A 16 VDC 80 29 7 3 4 3 4 TIG Process 70 Duty Cycle y 9 144 0 42 i p 0 05 0 03 Single Phase 100 A 24 VDC NEA 80V 28 1 E i i 3 2 3 2 Stick Process 80 Duty Cycle 9 149 0 42 0 05 0 03 Single Phase 125 A 15 VDC 80 23 0 2 6 2 6 TIG Process 100 Duty Cycle y 9 144 0 42 y 0 05 0 03 While idling 4 Low open circuit voltage while in Lift Arc on all models and Stick on models with stock numbers 907 036 and 907 037 VNormal open circuit voltage 80 volts is present while in the Stick process for models with stock number 907 220 NOTE Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit NOTE This unit is equipped with Auto Line The Auto Line circuitry automatically connects to 120 460 VAC single or three phase power without removing the cover to relink the power source OM 2233 Page 12 4 2 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of welding power source Curves of other set tings fall between curves shown 115VAC Input Amperes Other Input Voltages 12
11. drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 sparks 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 e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2233 Page 2 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prev
12. e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes PC DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage lm 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants procr ation Se laver les mains apr s manipulation Les batteries les bornes et autres accessoires contiennent du plomb et des com
13. liminer tout risque de feu tre vigilant et garder toujours un LES BOUTEILLES peuvent exploser extincteur la port e de main si elles sont endommagees e Le soudage effectu sur un plafond plancher paroi ou s paration D s hontelles d Gaz porci comenencia peut d clencher un incendie de l autre cote sous haute eso une bouteille est e e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des g e elle peut exploser Du fait que les bouteilles de r servoirs tambours ou conduites a moins qu ils n aient ete prepa gaz font normalement partie du proc d de soudage res Re conform ment a AWS F4 1 voir les normes de les manipuler avec pr caution s curit e Brancher le c ble de masse sur la pi ce le plus pr s possible de la e Prot ger les bouteilles de gaz comprim d une chaleur excessi zone de soudage pour viter le transport du courant sur une longue ve des chocs m caniques des dommages physiques du lai distance par des chemins inconnus ventuels en provoquant des tier des flammes ouvertes des tincelles et des arcs risques d lectrocution d tincelles et d incendie e Placer les bouteilles debout en les fixant dans un support sta e Ne pas utiliser le poste de soudage pour d geler des conduites tionnaire ou dans un porte bouteilles pour les emp cher de tom gel es ber ou de se renverser e Encas de non utilisation enlever la baguette d lectrode du porte e Tenirles bouteilles loign es
14. Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fi
15. Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by
16. Disconnect power before maintaining 3 Maintain more often during severe conditions Heplace unreadable labels 3 Months Clean and tighten weld terminals Replace Damaged Repair Or Replace Cracked Cables And Cords 6 Months Do not remove case when blowing out inside of unit see Section 6 2 ME Blow out inside During d heavy service clean p monthly 6 2 Blowing Out Inside Of Unit A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown 802 886 A OM 2233 Page 25 Troubleshooting Help Aids 7 All directions are in reference to the front of the unit All circuitry referred to Is located inside the unit 1 Output LED 2 High Temperature LED The Output LED turns on when power is turned on The LED is also used to indicate several machine malfunctions When one of the malfunctions listed below occurs the LED will first turn off for 1 5 seconds and then it will begin to blink The number of blinks corresponds to a Help message re lating to that malfunction After the LED blinks the appropriate number of times the LED will again turn off for 1 5 seconds and the sequence will start again The malfunctions that correspond to Help 2 3 4 5 and 9 are thermal related The High Temperature LED turns
17. OM 2233 Page 41 7 Hardware is common and not available unless listed i Figure 11 2 Panel Front w Components 202 508 E Item Dia Part No Mkgs No Description Quantit 11 2 Panel Front w Components Figure 11 1 Item 1 AAN ETE 194242 sa Panel FIONRESN escrita iii 1 PME eo 195647 Panel Front Lower ex ER AA A DA fa a 1 GE ETT ETET 202929 22 Panel Front UPPET serias beaa id bes paaa ds o EO Ss ER n ings 1 NC aio pecado 174992 Knob Pointer 840 Dia X 250 ID w Spring Clip 21 2 D cpu bet iria VU Spe 174991 Knob Pointer 1 250 Dia X 250 ID w Spring Clip 21 1 D ostio d EN ER 202323 Nameplate Miller Maxstar 200STR 1 Orne ci ne 202722 Nameplate Miller Maxstar 200STR CE Models Only 1 f a sati ene o 178355 Nut 375 32 54hex 25h Nyl Flange 62d 3 Dra dada E tss 202553 Rept Tw Lk Insul Fem Dinse Type 50 70 Series Wsl 2 EN 207253 css PUG GAS FINO an qure m uua alodio an Rio 1 Osiris and 200659 s Lead ISU SME ENNIUS 1 AAA nr ES 185712 Insulator Bulkhead Front 2 Oe ate ash ie eat ean ae 185713 Insulator Bulkhead Rear 1 2 jc T PIED 185714 Washer Tooth 20MM ID X 32MM OD 2 A E EE 185717 Nut M20 X 1 5 1 0625 Hex 19 H Locking
18. QD m Q A allaj e kjele i px eo K IS IG E JOE lo os fos os 6 AIS lo jos INIR ID lo PD Jos NIEN 106 o eo fn Ad o IN os l 308L LLI aO O tr E O LL O 6010 amp EA 6011 HER BU ME REN EH 3 32 yel Hep EE en me 702 Oo HEGE kr Ref S 087 985 A 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out electrode was lifted to high If electrode sticks to work piece use a quick twist to free it S 0049 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it OM 2233 Page 33 10 5 Positioning Electrode Holder End View of Work Angle Side View of Electrode Angle GROOVE WELDS End View of Work Angle Side View of Electrode Angle FILLET WELDS 10 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S 0053 A 10 7 Good Weld Bead Characteristics Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetr
19. ata dcn 3 o e eee 2 400 POZ us 200851 Circuit Card Assy Power Interconnect 1 400 P2 os 230162 Circuit Card Assy Power Interconnect CE ROHS 1 401 PC1 206129 Circuit Card Assy Inverter Control 1 401 POA uses 230166 Circuit Card Assy Inverter Control CE ROHS 1 402 PC10 200841 Circuit Card Assy Boost Control 1 402 PC10 230170 Circuit Card Assy Boost Control CE ROHS 1 403 POS oves 199506 Circuit Card Assy Input Filter CE Models Only 1 403 POS vade 230207 Circuit Card Assy Input Filter CE ROHS 1 0100 neue 229333 Screw M10 1 5 x 20 Hex Hd pln 8 8 Pld SemS 2 OOT csse 083883 Washer Lock 402 id x 0 709 od x 087t Stl Splitt mm 2 O 136343 Screw K50 x 20 Pan Hd phl Stl Pld Pt Thread Forming 2 Ol 229334 Screw M 5 8 x 35 pan hd phil stl pldsems 2 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor
20. de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT
21. gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes e lfinside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e 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 e 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 e 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 while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 2233 Page 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 burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a prope
22. mentally safe way Wear proper face hand and body protection Keep flammables away 2 1 2 Times 1 Grinding Wheel Radial Grindin i Causes ete Arc Pee eee Grind end of tungsten on fine grit hard abrasive wheel before welding Do not use NL MM lt gt wheel for other jobs or tungsten can become contaminated causing lower weld quality vB 2 Tungsten Electrode fee A 2 ceriated tungsten is recommended 3 Flat Diameter of this flat determines amperage Ideal Tungsten Preparation Stable Arc capacity 4 Straight Ground Grind lengthwise not radial OM 2233 Page 29 SECTION 9 GUIDELINES FOR GTAW TIG WELDING 9 1 Positioning The Torch ane Q Tan T Y Da 1 16 in Bottom View Of Gas Cup Om 2233 Page 30 gtaw 7 2006 Grinding the tungsten elec trode produces dust and fly ing sparks which can cause injury and start fires Use lo cal exhaust forced ventila tion at the grinder or wear an approved respirator Read MSDS for safety information Consider using cerium or lanthanum based tungsten instead of thoriated Tho rium dust contains low level radioactive material Proper ly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable
23. un harnais de s curit si l on doit travailler au dessus du sol Provoquer ugs ace dents moles ou dec Prud rs e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est BED TPR NORE d sous tension lorsque le courant est d livr la PAR ui sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le cable de retour de fa on obtenir un bon contact metal metal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique a la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sourc
24. 0 A 100 80 gt o s So ee 20 DIG Max 0 i ee 0 100 50 200 250 Amperes Amperage setting must be reduced to obtain currents less than highlighted data point 189 767 A OM 2233 Page 13 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load MAXSTAR 200 DUTY CYCLE CHART without overheating If unit overheats output stops and cooling fan runs Wait fifteen min 290 utes for unit to cool Reduce amper age or duty cycle before welding 200 aM Exceeding duty cycle can damage unit and void 0 TIG 115V INPUT warranty iT L M 150 L t I L p 100 3 STICK 115V INPUT 50 m 10 100 DUTY CYCLE 90 A 100 Duty Cycle For 115 Volt Single Phase Stick Process 125 A 9 100 Duty Cycle For 115 Volt Single Phase TIG Process 150 A 60 Duty Cycle For Stick Process Other Voltages 175 A 6096 Duty Cycle For TIG Process Other Voltages OG 6 Minutes Welding 4 Minutes Resting Overheating OM 2233 Page 14 0 2 lo Cow Minutes Reduce Duty Cycle 189 770 A 4 4 Selecting A Location 1 Identification Plate 2 Rating Label 3 Line Disconnect Device Dimensions And Weight Locate unit near correct input 34 7 Ib 15 7 kg without power cord power supply 37 3 Ib 16 9 kg with power cord A Special installation may be required where gasoline or vo
25. 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 8 Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide ade quate shielding gas coverage For example if tungsten is 1 16 in diameter gas cup should be a minimum of 3 16 in diameter Tungsten extension is the distance the tungsten extends out gas cup of torch The tungsten extension should be no greater than the inside diameter of the gas cup Arc length is the distance from the tungsten to the workpiece Ref ST 161 892 9 2 Torch Movement During Welding Tungsten Without Filler Rod Welding direction 75 x ODL LMG MSIL IEA VOLO A AED LL PETITE PP Form pool Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod Welding direction 75 15 2 nt d 97 47 27 4 P LE a ASEA NE B COU 7 E L p LE LOL Form pool Tilt torch Add filler metal UIT TITTA Remove rod Move torch to front of pool Repeat process 9 3 Positioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead T Joint ST 162 002 B 20 750 15 CE 10 Corner Joint i ANM IN z gt Lap Joint ST 162 003 S 0792 OM 2233 Page 31 SECTION 10 STICK WELDING SMAW GUIDELINES 10 1 Stick Welding Procedure A Weld current starts when electrode touches work piece Weld current can damage elec
26. And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in SU oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard 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 specification 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 7 Miller Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1515 SY tbol USdge cca xit ER EN anes moe aD EE a MeV TT A CIN AT E 1 12 AVC Welding Hazards oade iae Spec dH RE rs bid eme due moe dede me eo es 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 1 3 155 Principal Safety Standards 5 233 xx A RS RUE ne OUR ETC CR UC CR 4 16 EMP InformoallODrs 2 55 uus Ranae sw lla as pa oaks Hos CERE e deo o x Res a a
27. Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 10 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed OM 2233 Page 38 10 19 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed 10 20 Troubleshooting Waviness Of Bead D Dl Waviness Of Bead weld metal that is not parallel and does not cover jointformed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 10 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move E Base metal moves in the direction of the weld bead
28. LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion
29. MAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to orig
30. OM 2233 203 409Q O E 2007 04 Miller Processes j TIG GTAW Welding nu Pa Stick SMAW Welding Description E y ES 115 230 400 460 Volt Models W Autoline Arc Welding Power Source Maxstar 200 STR OWNER S MANUAL Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir Y E BL El Her 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 EG El jue ere ex e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance
31. PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or 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 e Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and
32. Res YR Rue ibid 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des Symboles sti ux qiios Gn eds P see bee Oe e oe ae aC ns 5 2 2 Dangers relatifs au soudage Parc 2 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de S curit su astra dnm ma dod dont tu Vu E RV a 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS CE Models 5 rrr rrt rh Rer mre We we noie aa mne 9 3 1 Warning Label D finitions sste sisit RV Sas dA eos REY dada dura RETE ME EDS cest 9 3 2 Manufacturers Rating Label S es retrar nere 11 3 3 Symbols And D finitions sesser oie atk a iO AUR wai a wo oe EU ae d UH ate den kunde 11 SECTION 4 INSTALLATION 2 22 0x1 moe urn QOO au eee ane t pave re tack uaa oos ewe M date 12 ds lu SVC CIE AMO IAS om A A ce DO Creme den ee nues 12 4 2 OMAP OTS CUNG sus iet eR Ca orne mani ASAS 13 43 Duly Cycle And OvetheallDg snore etd een rame Exc Ente Rr xm pense ES PRESS REPRE 14 4 4 SEEMA LOCA out a om abe do aded fem s dad Que qe ems Pa t basis oe Ca ete d 15 4 5 Weld Output Terminals And Selecting Cable Sizes 1 16 4 6 Remote 14 Receptacle Information mn
33. are 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 Warning Label Definitions 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 Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed 4 4 containers Arc rays can burn eyes and injure skin Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Become trained and read the instructions before working on the machine or welding Do not remove or paint over cover the label 179 310 A OM 2233 Page 9 S 179 309 A 3 2 WEEE Label For Products Sold Within The EU OM 2233 Page 10 S 185 836 Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from wiring can kill 2 Disconnect input plug or power before working on machine Hazardous voltage remains on input capacitors after power is turn
34. ation into Base Metal S 0052 B OM 2233 Page 34 10 8 Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 4 10 30 Angle Too Large ELECTRODE ANGLE er EE acc EEE Too Short Normal Too Long ARC LENGTH ER Normal TRAVEL SPEED 10 9 Electrode Movement During Welding Normally single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better Stringer Bead Steady Movement Along Seam Weave Bead Side to Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode S 0054 A OM 2233 Page 35 10 10 Butt Joints O 1 16 in 22 1 6 mm EM 10 11 Lap Joint 30 Or Less le y 2 Single Layer Fillet Weld Multi Layer Fillet Weld 10 12 Tee Joint 45 Or Less OM 2233 Page 36 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be fore final weld 2 Square Groove Weld Good for materials up to 3 16 in 5 mm thick 3 Single V Groove Weld Good for materials 3 16 3 4 in 5 19 mm thick Cut bevel with oxy acetylene or plasma
35. ce dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 10 15 Troubleshooting Excessive Spatter rae ET Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage OM 2233 Page 37 10 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 10 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions
36. ctrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e 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 e Properly install and ground this equipment according to its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT
37. cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength S 0063 S 0064 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 10 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 10 13 Weld Test 2 To 3 in t 51 76 mm 1 4 in EN 6 4 mm ZT 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown A good weld bends over but does not break S 0057 B 10 14 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpie
38. dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 Output Receptacles This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable 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 mm for metric use Select weld cable size for pulsing application at peak amperage value S 0007 E 4 6 Remote 14 Receptacle Information Socket Socket Information 7 REMOTE 14 Output to remote control O to 10 volts dc output to remote control D Remote control circuit common REMOTE OUTPUT CONTROL E 0 to 10 volts dc input command signal from remote control ST 802 541 CHASSIS K Chassis common The remaining sockets are not used OM 2233 Page 16 4 7 TIG Lift Arc DCEN Direct Current Electrode Negative Connections Turn off power before mak ing connections Positive Weld Output Terminal Connect work lead to positive weld output terminal 2 Negative Weld Output Terminal Connect TIG torch to negative weld output terminal 3 Gas Cylinder 4 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Clos
39. de et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort instructions aff rentes pour viter tout risque Les instructions en e l quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s raie e de dans la Section 2 5 Lireet amp Ne pas enrouler les c bles autour du corps ae pa i e Sila pi ce soud e doit tre mise la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en n 3 m me temps cause de la pr sence d une tension vide doubl e E UNE DECHARGE ELECTRIQUE peut e N utiiser qu un mat riel en bon tat R parer ou remplacer sur le 9 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut e Porter
40. des circuits de soudage ou autres lectrode ou couper le fil la pointe de contact circuits lectriques e Porter des v tements de protection exempts d huile tels que des e Ne jamais placer une torche de soudage sur une bouteille gaz gants en cuir une veste r sistante des pantalons sans revers des e Une lectrode de soudage ne doit jamais entrer en contact avec bottes et un casque une bouteille e Avant de souder retirer toute substance combustible de ses poches e Ne jamais souder une bouteille pressuris e risque d explosion telles qu un allumeur au butane ou des allumettes e Utiliser seulement des bouteilles de gaz protecteur r gulateurs e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B tuyaux et raccords convenables pour cette application sp cifi wa pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 2233 Page 6 que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape
41. dtunnel w Components Figure 11 1 Item 4 pov 195645 Panel Midplain Horizontal 1 D n LUE CE LE 198634 Bracket Front Heatsink Mtg 1 gt T 198633 c WING TUNNEL ass Teads burure SY UP RUSSE Laien Dod ee Rated o SR A 1 A dras 2323856734 A oo oda eto aic oda usitate ox 2 198652 Bracket Windtunnel Insulator 1 2 Cie oe eas te 209949 Heat Sink Module 1 Te eue 199497 Heat Sink Secondary Assembly 1 A EE 189787 s Choke NN pA 1 AA C9 a 151328 Capacitor Polyp Met Film 0047Uf 1000 Vdc W T CE Models Only 1 ba de Tera 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High CE Models Only 4 A eee 154408 Bushing Snap in Nyl 562 Id X 875 Mtg Hole Cent 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2233 Page 46 7 Hardware is common and not available unless listed 199 497 H Figure 11 6 Heat Sink Secondary Assembly Item Dia Part No Mkgs No Description Quantit Figure 11 6 Heat Sink Secondar
42. e valve 5 Regulator Flowmeter 6 Flow Adjust Typical flow rate is 15 cubic feet per hour 7 1 liters per minute Connect torch gas hose to regula tor flowmeter 7 Gas Valve Valve controls gas preflow and postflow Open valve on torch just before welding Tools Needed Dp 11 16 in 1 1 8 in 21 mm Ref 802 888 A OM 2233 Page 17 4 8 Stick DCEP Direct Current Electrode Positive Connections Turn off power before mak ing connections Negative Weld Output Terminal Connect work lead to negative weld output terminal 2 Positive Weld Output Terminal Connect electrode holder to posi tive weld output terminal Ref 802 888 A 4 9 Electrical Service Guide Actual input voltage cannot exceed 10 of minimum or 10 of maximum input voltages indicated in table Single Phase Single Phase B 10096 Duty 6096 Duty Three Um Duty Cycle Cycle y Input voltage 115 230 230 400 460 Input Amperes At Rated Output 25 22 13 1 7 4 6 4 Max Recommended Standard Fuse Rating In Amperes Time Delay 25 25 15 8 8 Normal Operating 35 30 20 10 10 Min Input Conductor Size In AWG 10 12 14 14 14 Max Recommended Input Conductor Length In Feet Meters 57 17 79 24 n o aoa Min Grounding Conductor Size In AWG 10 12 14 14 14 Reference 2005 National Electrical Code NEC 1 If a circuit breaker is used in place of a fuse choose a circuit breaker
43. ed off Do not touch fully charged Capacitors Always wait 60 seconds after power is turned off before working on unit OR Check input capacitor voltage and be sure it is near O before touching any parts When power is applied failed parts can explode or cause other parts to explode Flying pieces of parts can cause injury Always wear a face shield when servicing unit Always wear long sleeves and button your collar when servicing unit After taking proper precautions as shown connect power to unit Warning Watch Out There are possible hazards as shown by the symbols Falling equipment can cause injury and damage to unit Always lift and support unit using both handles Keep angle of lifting device less than 60 degrees Use a proper cart to move unit Do not use one handle to lift or support unit Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information 3 3 Manufacturer s Rating Label ACD PE ni 1A 10V 200A 18V U 115V e EMC 100 100 See Section 4 4 for location 7 Use rating label to de termine input power requirements Ic 1A 20V 200A 28V U 115V De Noson unv ES E BEA umm o9 Ju ae um 0 08 Ja owes um o 05 195 646 B
44. elds is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 2233 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables ar
45. en Or Green Yellow Grounding Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolate red conductor as shown 6 Input Power Cord 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 10 Over Current Protection Select type and size of over current protection using Section 4 9 fused dis connect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 2 04 Ref 802 136 A SECTION 5 OPERATION 5 1 Controls A Non CE Units NOW d 4 1 3 TIG Lift Arc 6 NOTE Green on nameplate indicates a TIG 3 DIG Control 5 Power On Troubleshooting Help Aids function Gray indicates a Stick function Light 1 Process Controls See Section 5 6 See Section 6 3 See Section 5 2 6 Power Switch 4 High Temperature Shutdown Light 2 Amperage Control Use switch to turn unit and indicator light See Section 5 5 See Section 4 3 On Off 202 323 B 802 889 OM 2233 Page 21 B For CE Units LP Y AM SCE e NOTE Green on nameplate indicates a TIG 3 DIG Control 5 Power On Troubleshooting Help Aids function Gray indicates a Stick function Light 1 Process Controls See Sectio
46. ent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e 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 e 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 mechani cal shocks physical damage 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 fit tings 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 over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of per
47. ent such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf 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 Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm gt Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling OM 2233 Page 3 1 5 Principal Safety Standards Safety in Welding
48. er Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les cables ensemble en les tordant ou en les enveloppant 2 Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 DEFINITIONS CE Models 3 1 Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with b
49. es de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber LES FUM ES ET LES GAZ peuvent e Se servir d une source lectrique courant lectrique UNIQUEMENT si etre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n Le soudage g n re des fum es et des gaz Leur cessaire se servir de la fonction de t l commande si l appareil en est inhalation peut tre dangereuse pour la sant quip e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e Alint rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e Sila ventilation est m diocre porter un res
50. g Tungsten Electrode Wear Clean gloves To Prevent Contamination Of Tungsten Amperage Range Gas Type Polarity Electrode Diameter DCEN Argon AC Argon Direct Current Electrode Negative Balance Control 65 Electrode Negative For Use With Mild Or Stainless Steel For Use With Aluminum 2 Ceria Orange Band 1 5 Lanthanum Gray Band Or 2 Thorium Red Band Alloy Tungstens 010 1 mm Up to 25 Up to 20 020 1 mm 15 40 15 35 040 1 mm 25 85 20 80 1 16 1 6 mm 50 160 50 150 3 32 2 4 mm 135 235 130 250 1 8 3 2 mm 250 400 225 360 5 32 4 0 mm 400 500 300 450 3 16 4 8 mm 500 750 400 500 1 4 6 4 mm 750 1000 600 800 Typical argon shielding gas flow rates are 11 to 35 cfh cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 8 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires Use local exhaust forced ventilation at the grinder or wear an approved respirator Read MSDS for safety infor mation Consider using tungsten containing ceria lanthana or yttria instead of thoria Grinding dust from thoriated electrodes contains low level radioactive material Properly dispose of grinder dust in an environ
51. g Welding 36 10510 But JONS 2 22 aes dan else utes ods RO En Gans Roe t de eh ES CE dust ed 37 POST Lap dot xus tale eds dex Grae rs EEG ees eae eae a ed quus Ea 37 10 12 dTeedolnt xis uc cade hernie este ar ogee UMS Ue SU VR cals EXER 37 TO 13 Weld Test sr rural adria aia S ut pe e S eels f 38 10 14 Troubleshooting Posh S a brasas Soe gers Sore oat A Oe RSS EE 38 10 15 Troubleshooting Excessive Spatter 0 ccc cece s 38 10 16 Troubleshooting Incomplete Fusion 2 39 10 17 Troubleshooting Lack Of Penetration 482 39 10 18 Troubleshooting Excessive Penetration 2 39 10 19 Troubleshooting Burn Through 2802 40 10 20 Troubleshooting Waviness Of Bead 40 10 212 Troubleshooting DISlOMION urs res ages ceeded HERE KEE eek eee eee eee EEE SSS EN 40 SECTION TT PARIS EIST sare tia tn e ctn o AAA Fr pa aUe Rete Da e E ita 42 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E
52. his happens Help 9 Display Indicates a short in the thermal protection circuitry located on the top heat sink Con tact a factory Authorized Service Agent if this happens 6 4 Troubleshooting Trouble Remedy No weld output unit completely inoperative Place line disconnect switch in On position see Section 4 10 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 10 Check for proper input power connections see Section 4 10 No weld output Output LED on Input voltage outside acceptable range of variation see Section 4 9 See Section 6 3 Troubleshooting Help Aids No weld output Overtemp LED on Unit overheated Allow unit to cool with fan On see Sections 4 3 and 6 3 Erratic or improper weld output Use proper size and type of weld cable see Section 4 5 Clean and tighten all weld connections see Section 4 5 Fan not operating Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc Use proper size tungsten see Section 8 Use properly prepared tungsten see Section 8 Reduce gas flow rate see Section 4 7 Tungsten electrode oxidizing and not re maining bright after conclusion of weld Shield weld zone from drafts Allow adequate postflow time to shield tungsten while it cools after welding stops Check and t
53. ighten all gas fittings see Section 4 7 Water in torch Refer to torch manual OM 2233 Page 27 SECTION 7 ELECTRICAL DIAGRAMS CE MODELS ONLY PC9 INPUT FILTER L1 IN L1 OUT Le C ED Le INLe OUT LEN i L3_INL3_OUT L3 O GRN VEL B i GND He GRN CHASSIS RED BLK 42 123456789011 PC10 BOOST CONTROL RC1 RC2 12345 687 78 9 10112 RC1 PC2 POWER INTERCONNECT RC3 1234356789011 1234367891011 1234367891011 1234353567 8 9 10 I 12 lt RC7 1 RC3 RC4 RC5 4 gt lt RC7 2 RC5 3 gt RCS amp PCi INVERTER CONTROL RCS 1 gt RCe PLGe RCS PLGS RC6 PLG6 RCe 1 RC7 PLG7 PN i RC A IA _ Z PLG PC3 WELD CONTROL OPERATOR INTERFACE RC1 PLG11 RC2 PLGi2 RC2 2 gt CHASSIS REVERENCE RETURN REFERENCE COMMON REFERENCE OUT K C E D RCI CE MODELS ONLY TN A RC1 PLG26 SALD RT1 amp WARNING ELECTRIC SHOCK HAZARD Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit POSITIVE NEGATIVE 202 314 B it Diagram Ircul Figure 7 1 C OM 2233 Page 28 SECTION 8 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_7 2006 Whenever possible and practical use DC weld output instead of AC weld output 8 1 Selectin
54. ignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute zl E ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne vanis plaqu en plomb ou au cadmium moins que le rev tement n ait de terre du sectionneur ou que la fiche du cordon est raccord e une t enlev dans la zone de soudure que l endroit soit bien ventil et en prise correctement mise la terre portant un respirateur alimentation d air Les rev tements et tous les e En effectuant les raccordements d entr e fixer d abord le conducteur m taux renfermant ces l ments peuvent d gager des fum es toxi de mise la terre appropri et contre v rifier les connexions ques en cas de soudage OM 2233 Page 5 LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et a la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage LES ACCUMULATIONS DE GAZ risquent de provoq
55. inal customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller
56. l 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 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away m 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 e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing ele
57. latile liquids are present see NEC Article 511 or CEC Section 20 17 1 4 in 438 mm 13 3 8 in 333 mm LR5071 SERIAL NO XXXXXXX3 Location And Airflow STOCK NO XXXXXXXXXXXXXX4 GR PROTECTED BY ONE OR MORE OF THE FOLLOWING US PATENTS XXXXXO5 200006 200007 XXXXXO09 XXXXX10 XXXXX11 XXXXX15 XXXXx 1 XX00024 XXXXX25 20000026 XXXXX32 XXXXX42 XXXXX47 XXXXX48 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY EN 60974 1 1A 10V 200A 18V PS 100 2 S b 200 175 150 Pd av w s v fans y y K A y 1A 20V 200A 28V 60 100 Bagn bd e 125 S Ga wx D Pax l4 eff 1 50 60 Hz 35 AAA VHS V v 4 LL ASIA A 2 Y y 4 Y ADV Y f fp Y Y f 18 in 1 50 60 Hz 17 460 mm S 50 60 Ha Us 2s0V 19 1 3A 50 60 Hz Ua n 6 SAN 500 Ua 9 5 IP23 802 886 A OM 2233 Page 15 4 5 Weld Output Terminals And Selecting Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30m Or Less 45 m 60 m 70m 90m 105 m 120 m Weld Output Terminals Turn off power before Weldi 10 60 60 100 connecting to weld out elaing Dut D o y uty 10 100 Duty Cycle put terminals Amperes Cycle Cycle Do not use worn
58. liser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester distance provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologuees de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut e Ne pas souder dans un endroit o des tincelles peuvent tomber sur des des substances inflammables affecter louie e Se prot ger ainsi que toute autre personne travaillant sur les lieux e Porter des protections approuv es pour les conte d S Sune ne GLP meta enano oreilles si le niveau sonore est trop lev e Des tincelles et des mat riaux chauds du soudage peuvent an passer dans d autres zones en traversant de petites issures et des ouvertures e Afin d
59. n 16 4 7 TIG Lift Arc DCEN Direct Current Electrode Negative Connections 17 4 8 Stick DCEP Direct Current Electrode Positive Connections 18 4 9 Blecirical Serice GUIS usse ah qeu red Qeitwa d qu naines Baar ene lo diode es qi eee aud d 18 4 10 Connecting Input POWELL deg dtm nie benne Ctt s ate xi t Rn Bur Cu koa a are Cu p Ran iat y 19 SECTION 5 OPERATION 4252 P9ePPDISG Rex RIEEeRRPUDIUEPRCerEORCPRDPEPDUERIRCLAEDEDREDPEE 20 De EEG IU NE ENE Lacie cr me nono na duo pe de cece rons pt cbt eo Dechy bea abode lr Sed tn 20 52 PrOCESS COMMON rs acne a ETUDES 22 9 9 CACCE Stant PrOCedUre s uo adu ein Ince ic eid ies i o ation it ananas 22 5 4 Stick Start Procedure Scratch Start Technique 23 5 5 Amperage Contool c cs cata aga ols whee ket Ke A A SERE wa Heg x beoe A RR 23 5 0 DIG CONTO ere 23 SECTION 6 MAINTENANCE AND TROUBLESHOOTING eee nnn 24 6 1 Routine Maintenance ire eee eae ES Red cea eer A e cea em ed exer ee o ees 24 6 2 Blowing Out Inside Of UN 4252 ark ads oe cot wale fds RSs cn annee EE EAT 24 6 3 Troubleshooting Help AS a Rr n aies ra EN ee Ru Seen 25 624 TOUDIGSHOOUNG PT ode ake we aw ek ely Soe Se wi er ate bleket shee band a 26 SECTION 7 ELECTRICAL DIAGRAMS sugar 27 SECTION 8 SELECTING AND PREPARING TUNGSTEN ELECTRODE 243 issue eee ee oes ees Cee ee eee TREES le 28 8 1
60. n 5 6 See Section 6 3 See Section 5 2 6 Power Switch 4 High Temperature Shutdown Light 2 Amperage Control Use switch to turn unit and indicator light See Section 5 5 See Section 4 3 On Off 202 722 A 802 889 OM 2233 Page 22 5 2 Process Control CE Model 1 Process Control Rotate knob up to select the Stick process Rotate knob down to se lect the TIG Lift Arc process Stick SMAW This is a DCEP di rect current electrode positive pro cess Make connections according to Section 4 8 TIG Lift Arc This is a DCEN di rect current electrode negative process in which the electrode must come in contact with the work piece to initiate an arc see Section 5 3 Make connections according to Section 4 7 TIG Lift Arc 5 3 Lift Arc Start Procedure Lift Arc Start With Lift Arc selected start arc as follows 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten elec trode to workpiece at weld start point Hold electrode to work piece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between 4 electrode and workpiece The Touch Seconds solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contamina
61. on along with the blinking Output LED A malfunction relating to Help O will cause the the Output LED to turn off and stay off but the High Temperature LED turns on and OM 2233 Page 26 stays on Help O Display Indicates a short in the thermal protection circuitry located on the bottom heat sink Contact a Factory Authorized Service Agent if this happens Help 1 Display Indicates a malfunction in the primary pow er circuit caused by an overcurrent condi tion in the primary IGBT switching circuit Contact a Factory Authorized Service Agent if this happens Help 2 Display Indicates an open in the thermal protection circuitry located on the bottom heat sink Contact a Factory Authorized Service Agent if this happens Help 3 Display Indicates the bottom heat sink has over heated The unit has shut down to allow the fan to cool it see Section 4 3 Operation will continue when the unit has cooled Help 4 Display Indicates an open in the thermal protection circuitry located on the top heat sink Con tact a Factory Authorized Service Agent if this happens Help 5 Display Indicates the top heat sink has overheated The unit has shut down to allow the fan to Cool it see Section 4 3 Operation will con tinue when the unit has cooled Help 8 Display Indicates a malfunction in the secondary power circuit of the unit There is a high open circuit condition Contact a Factory Authorized Service Agent if t
62. ound your body B m m 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 before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som _3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes NN Nr Ce groupe de symboles signifie Avertissement Attention Risques 2 1 r Symboles utilis s Symbole graphique d avertissement Attention Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures a prendre pour supprimer IF Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre gar
63. pirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur e Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxygene provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger l e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de d selon les cons
64. ple or any metal when threading welding wire E 3 1 4 California Proposition 65 Warnings STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat 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 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipm
65. pos s base de plomb produits chimiques dont l tat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences a
66. ps magnetiques et lectriques Le courant de soudage pendant son passage dans les cables de souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 2233 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Oth
67. r shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI 749 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection T 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e 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 e Do not weld on closed containers such as tanks
68. rounding Conductor 4 Disconnect Device Grounding L1 Terminal 5 Input Conductors L1 L2 And L3 L2 6 Disconnect Device Line Terminals L3 Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Over Current Protection Select type and size of over current protection using Section 4 9 fused dis connect switch shown Close and secure door on disconnect de vice Remove lockout tagout device and place switch in the On position Tools Needed SS 2 04 Ref 802 136 A OM 2233 Page 19 B Connecting Single Phase Input Power CLIZZZIZZY p VWs 8 GND PE Earth Ground Tools Needed pm m OM 2233 Page 20 installation must meet all National and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in put power before connecting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal 3 The Auto Line circuitry in this unit au tomatically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to any in put power between 120 and 460 VAC without removing cover to relink the power source 1 Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Gre
69. rr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiler ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent de
70. s cancers et des malformations cong nitales ou autres pro bl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation OM 2233 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des cham
71. sons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit HK FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other peo
72. ted Application Lift Arc is used for the DCEN GTAW process when HF Start method is not permitted or to re place the scratch method Do NOT Strike Like A Match OM 2233 Page 23 5 4 Stick Start Procedure Scratch Start Technique With Stick selected start arc as follows e 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like strik ing a match lift electrode slightly after touch ing work If arc goes out electrode was lifted to high If electrode sticks to workpiece use a quick twist to free it For models with stock number 907 220 normal open circuit voltage 80 volts is present before electrode touches workpiece For models with stock numbers 907 036 and 907 037 normal open circuit voltage is not present before electrode touches work piece only a low sensing voltage is present between electrode and workpiece 5 5 Amperage Control CE Model A 1 A Amperage Control Rotate knob clockwise to increase 80 bras amperage Min 200 amps A AMPERAGE ADJUST 5 6 DIG Control CE Model Dn 1 DIG Control Control increases SMAW short cir 40 9 6 cuit amperage at low arc voltage This allows the operator to use a very short arc length without stick ing the electrode Set control at O for normal welding amperage Turn clockwise to in crease short circuit amperage OM 2233 Page 24 SECTION 6 MAINTENANCE AND TROUBLESHOOTING 6 1 Routine Maintenance
73. the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DA
74. tronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece is clean be fore welding 2 Work Clamp 3 Electrode small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 10 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc With correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass Tools Needed li OM 2233 Page 32 stick 12 96 ST 151 593 10 2 Electrode and Amperage Selection Chart LE DIAMETER D fos 5 100 50 AMPERAGE RANGE 0 UU oy A 0 O1 Y i O C2 N 6010 Q 6011 EP EN 6013 EPEN FLA 7024 EP EN HORIZ L FILLET ALL LOW CAST IRON LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY DEEP D L MIN PREP ROUGH HIGH SPATTER GENERAL OW SMOOTH EASY MED FA OW PER ids E SRE PENETRATION u F r A A A A A LOW LOW DEN IE IA wee iol IDE lob j 12 AID Jo IN los RK lo LL LL LL T BE SMOOTH EASY FASTER 0 ON DI USAGE 4 O
75. uer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction e Porter un casque de soudage approuv muni de verres filtrants ap d air homologu propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous vo DES PI CES CHAUDES peuvent re l provoquer des br lures graves e Avoir recours des crans protecteurs ou a des rideaux pour prot ger les autres contre les rayonnements les blouissements et e Ne pas toucher des parties chaudes mains les tincelles pr venir toute personne sur les lieux de ne pas nues regarder l arc e Pr voir une p riode de refroidissement avant e Porter des v tements confectionn s avec des mati res r sistantes d utiliser le pistolet ou la torche et ignifuges cuir coton lourd ou laine et des bottes de protection AYIA LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent e Ne pas toucher aux pi ces chaudes uti
76. with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 2233 Page 18 4 10 Connecting Input Power PNG A Connecting Three Phase Input Power installation must meet all National and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in put power before connecting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal 3 The Auto Line circuitry in this unit au tomatically adapts the power source to the primary voltage being applied T Check input voltage available at site This unit can be connected to any in put power between 120 and 460 VAC PAN AANA A AANA IS without removing cover to relink the NE power source l 2 For Three Phase Operation 1 Input Power Cord E 2 Disconnect Device switch shown in d the OFF position 3 Green Or Green Yellow G
77. y Assembly Figure 11 5 Item 7 AA deat eaten 210783 s Heat CINK DIONE ut utei Ra Se e ta ence dene 1 CES DE eus 204820 Kit Diode Ultra Fast 1 D mauus HD1 198028 Transducer Current 100a Module Supply V 15v 1 d cat d FTT eos cs 211124 Thermistor Ntc 30k Ohm 25 Deg C 18 in Lead 1 Dad R2 C6 206021 Resistor Capacitor 1 OU oris REOS 1 199138 as RESISION capacitor Hardee deh gin dace Iq Ih aes de adhaesit bogs 1 Tin SET s 199952 Diode Power Module 50 Amp 600V 1 600 a aeneae A 207451 Screw 008 32 x 50 Pan Hd Phl Stl Pld 2 DO e tet ed k dish 231214 Screw 008 32 x 1 00 Pan Hd phl Stl Pld 1 COS CIC 207451 Screw 008 32 x 50 Pan Hd Phl Stl Pld SemS 1 604 9 207450 Screw 004 40 x 37 Pan Hd torx Stl Pld Cone Sems 4 5101 CUNT CETT 229331 Screw M 6 1 0 x 16 Pan Hd phl Stl Pld SemS 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2233 Page 47 7 Hardware is common and not available unless listed 199 493 B Figure 11 7 Base Assembly Item Dia

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