HIGH FREQUENCY ARC

STABILIZER
Owners Manual
and
Operation Guide

115-007 (86000), 115-008 (86001)

811-363-000.p65

4/9/01, 12:24 PM

811-363-000

TABLE OF CONTENTS
TABLE OF CONTENTS ................................................................................................................................ 2
IMPORTANT SAFETY INSTRUCTIONS ....................................................................................................... 3
SHOCK HAZARDS ...................................................................................................................................... 3
FLASH HAZARDS ....................................................................................................................................... 4
FIRE HAZARDS ........................................................................................................................................... 4
FUME HAZARDS ......................................................................................................................................... 5
COMPRESSED GASSES AND EQUIPMENT HAZARDS ........................................................................... 5
ADDITIONAL SAFETY INFORMATION ....................................................................................................... 6
PRODUCT DESCRIPTION ............................................................................................................................ 7
SPECIFICATIONS ....................................................................................................................................... 7
DUTY CYCLE .............................................................................................................................................. 7
PROVIDE REQUIRED POWER .................................................................................................................. 8
POWER REQUIREMENTS........................................................................................................................ 8
SPECIAL CONSIDERATIONS REGARDING HIGH FREQUENCY ENERGY ............................................ 8
INSTALLATION AND ASSEMBLY ................................................................................................................ 8
INSTALLATION CONSIDERATIONS ........................................................................................................... 8
SHIELDING AND GROUNDING THE AREA ............................................................................................... 9
CONNECT UNIT TO POWER SOURCE ..................................................................................................... 9
CONNECTION TO YOUR WELDING POWER SUPPLY ............................................................................ 9
CONNECTION OF WELDING OUTPUT LEADS ......................................................................................... 9
MAINTENANCE AND TROUBLESHOOTING ............................................................................................ 10
MANUFACTURERS LIMITED WARRANTY ............................................................................................... 11

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

IMPORTANT SAFETY INSTRUCTIONS

NEVER Stand, Sit, Lie, Lean On, Touch, or come into
physical contact in any way with any part of the
welding current circuit including:

SAVE THESE INSTRUCTIONS! DO

NOT OPERATE YOUR WELDER
UNTIL YOU HAVE READ AND
UNDERSTAND THESE
INSTRUCTIONS!

the work piece or any conductive material in

contact with it, the ground clamp, the electrode,
any metal parts on the electrode holder or TIG
torch
NEVER weld in a damp area or come in contact with a
moist or wet surface when welding.
NEVER attempt to weld if any part of clothing or body
is wet.
NEVER allow the welding equipment to come in
contact with water or moisture.
NEVER drag welding cables (or TIG torch assembly)
or welder power cord through or allow them to come
into contact with water or moisture.
NEVER touch welder, attempt to turn welder on or off,
or attempt to plug welder into power source if any part
of body or clothing is wet or damp, or if standing in or
in physical contact of any kind with water or moisture.
NEVER connect welder ground clamp to or weld on
electrical conduit.
NEVER alter power cord or power cord plug in any
way.
NEVER attempt to plug welder into power source if
ground prong on power cord plug is bent over, broken,
or missing.
NEVER allow welder to be connected to a power
source or attempt to weld if welder, welding cables (or
TIG torch assembly), welding site, or welder power
cord are exposed to rain, snow, sleet, mist, fog or
other forms of atmospheric precipitation, or mist or
spray from an ocean or other body of water.
NEVER carry coiled welding cables around shoulders,
or any other part of the body, when they are plugged
into the welder.
NEVER modify any wiring, ground connections,
switches, or fuses in this welding equipment.
ALWAYS wear welding gloves to help insulate hands
from welding circuit.
ALWAYS keep containers of water or other liquids far
enough away from welder and work area so that if
spilled, the liquid could not possibly come in contact
with the welder, welding cables (or TIG torch
assembly), welder power cord, the work piece being
welded, or any other part of the electrical welding
circuit.
ALWAYS replace any cracked or damaged parts that
are insulated or act as insulators such as welding
cables (or TIG torch assembly), power cord, or
electrode holder IMMEDIATELY.

ELECTRIC SHOCK CAN KILL!

ARC RAYS CAN INJURE EYES AND BURN SKIN!
FIRE OR EXPLOSION CAN CAUSE DEATH,
INJURY, AND PROPERTY DAMAGE!
FUMES, GASSES, AND VAPORS CAN CAUSE
DISCOMFORT, ILLNESS, AND DEATH!
IMPROPER HANDLING AND MAINTENANCE OF
COMPRESSED GAS CYLINDERS AND
REGULATORS CAN RESULT IN SERIOUS INJURY
OR DEATH!
IMPORTANT! DO NOT ATTEMPT OPERATION of
this welding equipment until reading and
understanding the following safety instructions to
reduce risk of DEATH, INJURY, AND PROPERTY
DAMAGE.

SHOCK HAZARDS

ELECTRIC SHOCK CAN KILL! To reduce risk of

death from electric shock, read, understand, and follow
the following safety instructions. In addition, make
certain that anyone else who uses this welding
equipment or is a bystander in the welding area
understand and follow these safety instructions as
well.

HIGH FREQUENCY RADIATION

Electrical equipment utilizing high frequency
energy in any way is capable of radiating electrical
interference. Read and follow instructions given
later in this manual to make sure installation is
such that interference is minimized.
Wearers of heart pacemakers and other electronic
equipment vital to life should check with the life
support manufacturer and their physician to
determine if a hazard exists.
Protect hands and all body parts that may come in
contact with the welding circuit. High frequency energy
can cause painful burns.

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

FLASH HAZARDS

FIRE HAZARDS

ARC RAYS CAN INJURE EYES AND BURN SKIN!

To reduce risk of injury from arc rays, read,
understand, and follow the following safety
instructions. In addition, make certain that anyone else
that uses this welding equipment, or is a bystander in
the welding area, understands and follows these
safety instructions as well.
NEVER look at an electric arc without proper
protection. A welding arc is extremely bright and
intense and, with inadequate or no eye protection, the
retina can be burned, leaving a permanent dark spot in
the field of vision. A shield or helmet with a number 10
shade filter lens (minimum) must be used.
NEVER strike a welding arc until all bystanders and
you (the welder) have welding shields and/or helmets
in place.
NEVER wear a cracked or broken helmet and replace
any cracked or broken filter lenses IMMEDIATELY.
NEVER allow the uninsulated portion of the electrode
holder to touch the ground clamp or grounded work to
prevent an arc flash from being created on contact.
ALWAYS provide bystanders with shields or helmets
fitted with a #10 shade filter lens.
ALWAYS wear protective clothing. The intense light of
the welding arc can burn the skin in much the same
way as the sun, even through light-weight clothing.
Wear dark clothing of heavy material. The shirt worn
should be long sleeved and the collar kept buttoned to
protect chest and neck.
ALWAYS protect against REFLECTED ARC RAYS.
Arc rays can be reflected off shiny surfaces such as a
glossy painted surface, aluminum, stainless steel, and
glass. It is possible for your eyes to be injured by
reflected arc rays even when wearing a protective
helmet or shield. If welding with a reflective surface
behind you, arc rays can bounce off the surface, then
off the filter lens on the inside of your helmet or shield,
then into your eyes. If a reflective background exists in
your welding area, either remove it or cover it with
something nonflammable and non-reflective. Reflected
arc rays can also cause skin burn in addition to eye
injury.

FIRE OR EXPLOSION CAN CAUSE DEATH,

INJURY, AND PROPERTY DAMAGE! To reduce risk
of death, injury, or property damage from fire or
explosion, read, understand, and follow the following
safety instructions. In addition, make certain that
anyone else that uses this welding equipment, or is a
bystander in the welding area, understand and follow
these safety instructions as well. REMEMBER! Arc
welding by nature produces sparks, hot spatter, molten
metal drops, hot slag, and hot metal parts which can
start fires, burn skin and damage eyes.
NEVER wear gloves or other clothing that contain oil,
grease, or other flammable substances.
NEVER wear flammable hair preparations.
NEVER weld in an area until it has been checked and
cleared of combustible and/or flammable materials. BE
AWARE that sparks and slag can fly 35 feet and can
pass through small cracks and openings. If work and
combustibles cannot be separated by a minimum of 35
feet, protect against ignition with suitable, snug-fitting,
fire resistant covers or shields.
NEVER weld on walls until checking for and removing
combustibles touching the wall on the other side.
NEVER weld, cut, or perform other hot work on used
barrels, drums, tanks, or other containers that
contained a flammable or toxic substance. The
techniques for removing flammable substances and
vapors in order to make a used container safe for
welding or cutting are quite complex and require
special education and training.
NEVER strike an arc on a compressed gas or air
cylinder or other pressure vessel. Doing so will create
a brittle area that can result in a violent rupture
immediately or at a later time as a result of rough
handling.
NEVER weld or cut in an area where the air may
contain flammable dust (such as grain dust), gas, or
liquid vapors (such as gasoline).
NEVER handle hot metal, such as the work piece or
electrode stubs, with bare hands.
ALWAYS wear leather gloves, heavy long sleeve shirt,
cuffless trousers, high-topped leather shoes, helmet,
and cap. As necessary, use additional protective
clothing such as leather jacket or sleeves, fire resistant
leggings, or apron. Hot sparks or metal can lodge in
rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and pockets
eliminated from the front.

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

NEVER weld in a confined area unless it is being

ventilated or the operator (and anyone else in the
area) 4 wearing an air-supplied respirator.
NEVER bring gas cylinders into or allow gas leaks in a
confined space. Leaked gas can rapidly reduce
oxygen concentration levels in a confined space.
ALWAYS shut off shielding gas supply at its source
before leaving a confined area and check to make
sure the area is safe before reentering it.
ALWAYS stop welding if you develop momentary eye,
nose, or throat irritation as this indicates inadequate
ventilation. Stop work and take necessary steps to
improve ventilation in the welding area. Do not resume
welding if physical discomfort persists.

ALWAYS have a fire extinguishing equipment handy

for instant use! A portable chemical fire extinguisher,
type ABC, is recommended.
ALWAYS wear ear plugs when welding overhead to
prevent spatter or slag from falling into ear.
ALWAYS make sure welding area has a good, solid,
safe floor, preferably concrete or masonry, not tiled,
carpeted, or made of any other flammable material.
ALWAYS protect flammable walls, ceilings, and floors
with heat resistant covers or shields.
ALWAYS check welding area to make sure it is free of
sparks, glowing metal or slag, and flames before
leaving the welding area.

FUME HAZARDS

COMPRESSED GASSES AND

EQUIPMENT HAZARDS

FUMES, GASSES, AND VAPORS CAN CAUSE

DISCOMFORT, ILLNESS, AND DEATH! To reduce
risk of discomfort, illness, or death, read, understand,
and follow the following safety instructions. In addition,
make certain that anyone else that uses this welding
equipment or is a bystander in the welding area,
understands and follows these safety instructions as
well.
NEVER weld in an area until it has been checked for
adequate ventilation as described in ANSI standard
#Z49.1. If ventilation is not adequate to exchange all
fumes and gasses generated during the welding
process with fresh air, do not weld unless you (the
welder) and all bystanders are wearing air-supplied
respirators.
NEVER heat metals coated with or containing
materials that produce toxic fumes, such as
galvanized steel, unless the coating is removed, the
area is well ventilated, or the operator and all
bystanders wear air-supplied respirators.
NEVER weld, cut, or heat lead, zinc, cadmium,
mercury, beryllium, or similar metals without seeking
professional advise and inspection of the ventilation of
the welding area. These metals produce EXTREMELY
TOXIC fumes which can cause discomfort, illness, and
death.
NEVER weld or cut in areas that are near chlorinated
solvents. Vapors from chlorinated hydrocarbons, such
as trichloroethylene and perchloroethylene, can be
decomposed by the heat of an electric arc or its
ultraviolet radiation to form PHOSGENE, a HIGHLY
TOXIC gas, along with other lung and eye-irritating
gasses. Do not weld or cut where these solvent vapors
can be drawn into the work area or where the
ultraviolet radiation can penetrate to areas containing
even very small amounts of these vapors.

IMPROPER HANDLING AND MAINTENANCE OF

COMPRESSED GAS CYLINDERS AND
REGULATORS CAN RESULT IN SERIOUS INJURY
OR DEATH! To reduce risk of injury or death from
compressed gasses and equipment hazards, read,
understand, and follow the following safety
instructions. In addition, make certain that anyone else
who uses this welding equipment or is a bystander in
the welding area understands and follows these safety
instructions as well.
NEVER use flammable gasses with TIG welders. Only
inert or non-flammable gasses are suitable for TIG
welding. Examples are Carbon Dioxide, Argon,
Helium, etc. or mixtures of more than one of these
gasses.
NEVER attempt to mix gasses in or refill a cylinder
yourself.
NEVER expose cylinders to excessive heat, sparks,
slag, and flame, etc. Cylinders exposed to
temperatures above 130 degrees F. will require water
spray cooling.
NEVER expose cylinders to electricity of any kind.
NEVER use cylinder or its contents for other than its
intended use. Do not use as a support or roller.
NEVER locate cylinders in passageways or work
areas where they may be struck.
NEVER lift cylinders off the ground by their valves or
caps or with chains, slings, or magnets.
NEVER use a wrench or hammer to open a cylinder
valve that cannot be opened by hand. Notify your
supplier.

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

ADDITIONAL SAFETY
INFORMATION

NEVER modify or exchange gas cylinder fittings.

NEVER deface or alter name, number, or other
markings on a cylinder. It is illegal and hazardous.
NEVER use cylinders without the name of the gas
marked on the cylinder. Do not rely on cylinder color to
identify the content.
NEVER connect a regulator to a cylinder containing
gas other than that for which the regulator was
designed.
NEVER attempt to make regulator repairs. Send faulty
regulators for repair to manufacturers designated
repair center.
NEVER attempt to lubricate regulator.
ALWAYS handle cylinders carefully to prevent leaks
and damage to their walls, valves, or safety devices.
ALWAYS secure cylinders with a steel chain so that
they cannot be knocked over.
ALWAYS protect cylinder, especially valve, from
bumps, falls, falling objects, and weather.
ALWAYS make sure cylinder cap is securely in place,
on the cylinder, whenever cylinder is moved.
ALWAYS remove faulty regulator from service
immediately for repair (first close cylinder valve) if any
of the following occur:

For additional information concerning welding safety,

refer to the following standards and comply with as
applicable.
ANSI Standard Z49.1 SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 NW Le Jeune Road, Miami, FL
33126 Telephone (800) 443-9353, Fax (305) 4437559 www.amweld.org or www.aws.org
ANSI Standard Z87.1 SAFE PRACTICE FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 11 West 42nd
St., New York, NY 10036 Telephone (212) 642-4900,
Fax (212) 398-0023 www.ansi.org
NFPA Standard 51B CUTTING AND WELDING
PROCESS obtainable from the National Fire
Protection Association, 1 Batterymarch Park, P.O.
Box 9101, Quincy, MA 02269-9101 Telephone (617)
770-3000, Fax (617) 770-0700 www.nfpa.org
CGA Pamphlet P-I SAFE HANDLING OF
COMPRESSED GASSES IN CYLINDERS
obtainable from the Compressed Gas Association,
1725 Jefferson Davis Highway, Suite 1004, Arlington,
VA 22202-4102 Telephone (703) 412-0900 Fax
(703) 412-0128 www.cagnet.com
OSHA Standard 29 CFR, Part 1910, Subpart Q.,
WELDING, CUTTING AND BRAZING obtainable
from your state OSHA office or U. S. Dept. of Labor
OSHA, Office of Public Affairs, Room N3647, 200
Constitution Ave. Washington, DC 20210
www.osha.gov
CSA Standard W117.2 Code for SAFETY IN
WELDING AND CUTTING. obtainable from
Canadian Standards Association, 178 Rexdale Blvd.
Etobicoke, Ontario M9W 1R3 www.csa.ca
American Welding Society Standard A6.0.
WELDING AND CUTTING CONTAINERS WHICH
HAVE HELD COMBUSTIBLES. obtainable from
the American Welding Society, 550 NW Le Jeune
Road, Miami, FL 33126 Telephone (800) 443-9353,
Fax (305) 443-7559 www.amweld.org or
www.aws.org

Gas leaks externally, delivery pressure continues

to rise with down steam valve closed, and/or
gauge pointer does not move off the stop pin
when pressurized or fails to return to the stop pin
after pressure is released.

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

PRODUCT DESCRIPTION
DUTY CYCLE

Your High Frequency Arc Stabilizer is designed for use

in either AC or DC shielded metal arc welding
(SMAW), otherwise known as stick welding. It is also
used as pan of a Tungsten Inert Gas (GTAW, TIG or
Heliarc) welding setup.
The High Frequency Arc Stabilizer is a supplement to
the standard arc welding power supply.
It consists of a spark gap type oscillator which
superimposes high frequency energy onto the welding
current by means of an air core coupling transformer.
The secondary of the air core transformer is in series
with the arc current and carries the full welding current.
There are several benefits to adding high frequency to
the welding output:

The duty cycle rating of a unit tells the operator how

long he or she can weld and how long the unit must
rest and cool. It is expressed as a percentage of 10
minutes (the industry recognized cycle time) and
represents the maximum welding time allowed, with
the balance of the 10 minute cycle required for cooling.
The High Frequency Arc Stabilizer is rated at 20%
duty cycle. NOTE: The use of a high frequency unit
may require derating of the welding power supply.
Consult the manufacturer of the power supply to verify
the duty cycle of the power supply when used with a
high frequency unit. Typically the duty cycle is reduced
by 1/3rd when used in this manner.

1. The welding arc may be started without touching

the electrode to the work piece.
2. Better arc stability and arc cleaning action is
obtained.
3. A longer arc is possible - this is particularly useful
with some types of welding rods.
4. Welding electrodes have longer life because
touch starting is eliminated.
5. A wider range of welding current can be used for
any specific welding electrode.
6. When used with a Tungsten Inert Gas (TIG,
GTAW) Torch, aluminum and magnesium may be
welded with ease.

Duty Cycle
Rating

Maximum
Welding Time

Required
Resting Time

20%
40%
60%
80%
100%

2 Minutes
4 Minutes
6 Minutes
8 Minutes
10 Minutes

8 Minutes
6 Minutes
4 Minutes
2 Minutes
0 Minutes

DO NOT CONSTANTLY EXCEED THE DUTY CYCLE

OR DAMAGE TO THIS HIGH FREQUENCY UNIT
WILL RESULT!

SPECIFICATIONS
Primary Volts: 115 VAC, 60 Hz.
Secondary Volts: 3500 V
Maximum Input Welding Current: 295 A AC or DC
Duty Cycle 20%
NOTE: This unit is designed for use with electric
welding power supplies ONLY! It should
not be used with an engine driven welding
generator unit. The frequencies generated
within the High Frequency Arc Stabilizer
will not synchronize properly with the
output of an AC welding generator.

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

INSTALLATION AND ASSEMBLY

PROVIDE REQUIRED POWER

machine case. It may be very noticeable if the unit is

not fully assembled with all cabinet screws secured or
if the unit is not properly grounded.
This unit is adequately shielded to prevent direct
radiation of noticeable consequence assuming it is
properly grounded.

POWER REQUIREMENTS
DO NOT OPERATE THIS UNIT if the ACTUAL power
source voltage is less than 105 volts AC or greater
than 132 volts AC. Contact a qualified electrician if this
problem exists. Improper performance and/or damage
to the unit will result if operated on inadequate or
excessive power.
ELECTRIC SHOCK CAN KILL! FIRE CAN KILL,
INJURE, AND CAUSE PROPERTY DAMAGE! To
reduce the risk of electric shock and fire, connect only
to properly grounded and fused outlets. NEVER
ALTER the AC power cord or power cord plug
provided on the unit. NEVER ALTER an extension
cord or extension cord plugs.

2. Direct Feed-Back to Power Line

High frequency energy may get into the power line by
direct coupling inside the welder or the high frequency
unit. The power line then acts as an antenna, emitting
the high frequencies.
By using proper shielding techniques given below, this
can be prevented.
3. Direct Radiation from the Welding Leads
Direct radiation from the welding leads, while very
pronounced, decreases rapidly with distance from the
leads themselves. Using as short of a welding lead set
as possible, you can reduce the interference greatly.
The intensity and frequency of the radiation can be
altered over wide ranges by simply changing the
locations and positions of the welding leads and the
work. Keeping the work and ground leads close
together and unlooped can help a great deal.

SPECIAL CONSIDERATIONS
REGARDING HIGH
FREQUENCY ENERGY
Electrical equipment utilizing high frequency
energy in any way is capable of radiating electrical
interference. Read and follow instructions given
later in this manual to make sure installation is
such that interference is minimized.
Wearers of heart pacemakers and other electronic
equipment vital to life should check with the life
support manufacturer and their physician to
determine if a hazard exists.
Protect hands and all body parts that may come in
contact with the welding circuit. High frequency energy
can cause painful burns.
High frequency energy has certain undesirable
characteristics which should be eliminated or
minimized when welding. Any equipment utilizing high
frequency energy in any way is capable of radiating
interference if not properly installed. Since the high
frequency unit is a basic type of radio transmitter, it
may cause interference with the reception of nearby
radio and television receivers as well as superimpose
electronic pulses in solid state devices nearby.
Therefore, protection must be provided to stop leakage
of the high frequency energy as much as possible.
In High Frequency Arc Stabilizer applications,
interfering radiation can escape in four distinct
methods:

4. Pick-Up and Radiation from Power Lines

Even though welding lead radiation falls off rapidly with
distance, the field strength in the immediate vicinity of
the welding area may be extremely high. Unshielded
wiring and ungrounded metallic objects in this strong
field area may pick up the direct radiation, conduct the
energy for some distance, and produce a strong
interference in another area.
This is usually the most troublesome source of
interference, but careful adherence to the shielding
and grounding instructions given below will minimize
the problem.

INSTALLATION
CONSIDERATIONS
To minimize the effects of high frequency energy
radiating out of the welding area, it is important to
provide shielding to the electrical wiring and other
conductive items in the welding area. A zone of
approximately 50 feet around, above, and below the
weld area is susceptible to high frequency generated
by the unit and the arc. Listed below are guidelines in
preparing the weld area and the building.

1. Direct Radiation from the Welding Machine

This is radiation that escapes directly from the welding

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

SHIELDING AND GROUNDING

THE AREA

CONNECTION TO YOUR
WELDING POWER SUPPLY

All building wiring within 50 feet of the welding area

should be shielded with solid metallic conduit. The use
of helically wrapped metal conduit is not sufficient to
effectively shield the wiring. Only solid conduit should
be used and care should be taken to insure that
connections at connection points of the conduit are
good. A good suggestion is to use copper strap across
connection points of the conduit to make the ground
complete.
The ground of the primary power system must be at
least 8 feet into moist soil and should be connected to
the shielding conduit with as short as possible of a
connecting wire.
When welding in a metal building, it is important that
the building itself be properly grounded. Welding within
a metal building does not improve or detract from the
high frequency energy radiated from the weld area.

There are two leads coming from the front of the High
Frequency Arc Stabilizer. These are the welding power
input leads. They are placed into the mating
receptacles on the front of your welding power supply.
The lead marked TO WELDER GROUND is placed
into the ground jack of the welder, the lead marked
TO WELDER OUTPUT is placed in the output jack of
the welder.
When welding with DC current, select the polarity with
these leads by placing the cables as shown in the
following chart:

NOTE: All changes in power and lighting wiring

should be made by qualified personnel
only and be done in accordance with the
National Electrical Code as well as any
local codes and requirements.

DC Straight
Polarity

DC Reverse
Polarity

Connect TO WELDER
GROUND to the Welders
Positive Output

Connect TO WELDER
GROUND to the Welders
Negative Output

Connect TO WELDER
OUTPUT to the Welders
Negative Output

Connect TO WELDER
OUTPUT to the Welders
Positive Output

If your welding power supply does not have plug-in

style output jacks, obtain part number 2806, Adapter
Fitting Kit, to adapt your existing welder output cables
for use with this unit. See your dealer for details.

CONNECT UNIT TO POWER

SOURCE
1. DO NOT ALTER the AC power cord or powercord
plug on this unit. Doing so may VOID THE
WARRANTY. If the units AC power cord plug
does not mate with your existing receptacle, have
an appropriate receptacle installed by a qualified
electrician in accordance with the National
Electrical Code and local codes and ordinances.
Do not use any adapters between the units AC
power cord plug and AC power source receptacle.

CONNECTION OF WELDING
OUTPUT LEADS
Always place the electrode of the welding circuit in the
output receptacle marked TO TIG TORCH even if not
using a TIG Torch. The ground cable is always placed
in the receptacle marked TO WORK GROUND.

2. Make sure the POWER SWITCH on the front of

the unit is turned to its OFF position. Then plug
the units power cord plug into the AC power
source receptacle.

811-363-000.p65

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

MAINTENANCE AND TROUBLESHOOTING

The spark gaps inside the High Frequency Arc
Stabilizer have been pre-set at the factory. During
operation, this spark gap setting will gradually increase
due to erosion of the spark gap contacts. The spark
gap should be checked and readjusted after every 200
hours of operation. Variations in spark gap distance
can lead to excessive high frequency radiation being
emitted.
WARNING: High voltage is present inside the unit
when plugged in. Unplug unit before servicing!
To adjust the spark gap:

3. The spark gap should be set at .007-.008". Use a

.007 feeler gauge and insert between the
contacts.
4. Push the end contacts (one at a time) toward the
center fixed contact until the gaps between the
contacts are the against the feeler gauge.
5. Tighten the set screws securely and recheck the
gap, making sure that the .007" feeler will slide
through, but a .009" gauge will not.
6. Clean dust, dirt, grease, etc. from your unit. Airblow any dust and dirt that may have accumulated
inside.

1. Remove the cover of the cabinet.

2. Loosen the set screws that hold the two outside
contacts.

7. Reinstall the cover.

10

811-363-000.p65

10

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM

MANUFACTURERS LIMITED WARRANTY

purchase for the High Frequency Arc Stabilizer but is
void if it has been abused, altered, misused, or
improperly packaged and damaged when returned for
repair.
Some states do not permit the limitation of warranties
or limitation of consequential or incidental damages, so
the above disclaimer and limitation may not apply to
you. This warranty gives you specific legal rights, and
you may also have other rights which vary from state
to state.
TO OBTAIN SERVICES UNDER THIS WARRANTY:

The manufacturer warrants that for 1 year from date of

purchase , it will repair, at no charge for parts or labor,
the High Frequency Arc Stabilizer proven defective in
material or workmanship. If after reasonable efforts by
the manufacturer, the unit is deemed unrepairable, the
manufacturer will, at its option, refund the original
purchase price or supply a replacement unit.
THE TERMS OF THE MANUFACTURERS LIMITED
WARRANTY CONSTITUTE THE BUYERS SOLE
AND EXCLUSIVE REMEDY. THE IMPLIED
WARRANTIES OR MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE
LIMITED IN DURATION TO THIS EXPRESS
WARRANTY. AFTER 1 YEAR FROM DATE OF
PURCHASE FOR UNIT, ALL RISK OF LOSS, FROM
WHATEVER REASON, SHALL BE UPON THE
PURCHASER.
THE MANUFACTURER SHALL NOT BE LIABLE FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES
UNDER ANY CIRCUMSTANCES: THE
MANUFACTURERS LIABILITY, IF ANY, SHALL
NEVER EXCEED THE PURCHASE PRICE OF THIS
PRODUCT, REGARDLESS OF WHETHER LIABILITY
IS PREDICATED UPON BREACH OF WARRANTY
(EXPRESSED OR IMPLIED), NEGLIGENCE, STRICT
TORT OR ANY OTHER THEORY.
This warranty extends to each person who acquires
lawful ownership within one year of the original retail

1. Owner pays transportation charges to the nearest

service center location.
2. Owner may avoid transportation charges, if he
wishes, by calling WELDER SERVICE, at one of
the telephone numbers listed below, for free
diagnosis and immediate shipment of replacement
parts. The owner, in this case, assumes the
responsibility for installation of parts.
For Service Center Locations call:
Welder Service
In Minneapolis: (952) 884-3211
Toll Free: (800) 328-2921

11

811-363-000.p65

11

115-007 (86000), 115-008 (86001)

4/9/01, 12:24 PM