Professional Documents
Culture Documents
Syncrowave 180 SD Manual
Syncrowave 180 SD Manual
October 2004
Processes
TIG (GTAW) Welding
Description
Syncrowave 180 SD
Mil_Thank 7/03
TABLE OF CONTENTS
Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
OM-360 Page 1
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion. D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks, going near arc welding, gouging, or spot
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot welding operations.
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. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see
gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder − explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
OM-360 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OM-360 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
(phone: 305-443-9353, website: www.aws.org). ternational.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard ANSI Standard Z87.1, from American National Standards Institute, 11
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi- West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
ami, FL 33126 (phone: 305-443-9353, website: www.aws.org). website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
sparky.org). 617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
OSHA, Occupational Safety and Health Standards for General Indus-
from Compressed Gas Association, 1735 Jefferson Davis Highway,
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
site: www.cganet.com).
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices−−phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale 312−353−2220,website: www.osha.gov).
OM-360 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
OM-360 Page 5
LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu-
ser des brûlures oculaires et cuta- vent causer des blessures ou même
nées. la mort.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) suscep- D Couper l’alimentation en gaz protecteur en cas de
tibles de causer des brûlures oculaires et cutanées. non utilisation.
Des étincelles sont projetées pendant le soudage. D Veiller toujours à bien ventiler les espaces confinés ou porter un respira-
D Porter un masque de soudage muni d’un filtre de la nuance adéquate teur à adduction d’air agréé.
pour se protéger le visage et les yeux pendant le soudage ou pour re-
garder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque. LES PIÈCES CHAUDES peuvent cau-
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat ser des brûlures graves.
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc. D Ne pas toucher les pièces chaudes à main nue.
D Porter des vêtements de protection en matière durable et ignifuge
D Prévoir une période de refroidissement avant
(cuir ou laine) et des chaussures de sécurité.
d’utiliser le pistolet ou la torche.
LE SOUDAGE peut causer un incen-
die ou une explosion. LES CHAMPS MAGNÉTIQUES peuvent
Le soudage effectué sur des récipients fermés tels que perturber le fonctionnement des stimu-
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées lateurs cardiaques.
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des D Les personnes qui portent un stimulateur cardiaque
incendies et des brûlures. Le contact accidentel de l’électrode avec tout doivent se tenir à distance.
objet métallique peut causer des étincelles, une explosion, un surchauf-
fement ou un incendie. Avant de commencer le soudage, vérifier et D Ils doivent consulter leur médecin avant de s’appro-
s’assurer que l’endroit ne présente pas de danger. cher d’un lieu où on exécute des opérations de sou-
dage à l’arc, de gougeage ou de soudage par points.
D Se protéger et protéger les tiers de la projection d’étincelles et de mé-
tal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des LE BRUIT peut affecter l’ouïe.
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m Le bruit de certains processus et équipements peut
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneuse- affecter l’ouïe.
ment avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer D Porter des protecteurs d’oreille agréés si le niveau
même par des fissures et des ouvertures de petites dimensions. sonore est trop élevé.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-
mité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une Les BOUTEILLES endommagées
cloison peut déclencher un incendie de l’autre côté. peuvent exploser.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à Les bouteilles de gaz protecteur contiennent du gaz
l’AWS F4.1 (voir les normes de sécurité). sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
D Brancher le câble sur la pièce le plus près possible de la zone de sou- normalement partie du procédé de soudage, les
dage pour éviter que le courant ne circule sur une longue distance, par manipuler avec précaution.
des chemins inconnus, et ne cause des risques d’électrocution et d’in-
cendie. D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
D Ne pas utiliser le poste de soudage pour dégeler des conduites ge- chocs mécaniques, du laitier, des flammes nues, des étincelles et des
lées. arcs.
D En cas de non utilisation, enlever la baguette d’électrode du porte− D Placer les bouteilles debout en les fixant dans un support stationnaire
électrode ou couper le fil au raz du tube−contact. ou dans un porte−bouteilles pour les empêcher de tomber ou de se
D Porter des vêtements de protection exempts d’huile tels que des renverser.
gants en cuir, une chemise en tissu épais, des pantalons sans revers, D Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
des chaussures montantes et un masque. cuits électriques.
D Avant de souder, retirer tout produit combustible de ses poches, tel D Ne jamais poser une torche de soudage sur une bouteille de gaz.
qu’un briquet au butane ou des allumettes. D Ne jamais mettre une électrode de soudage en contact avec une bou-
teille de gaz.
LES PARTICULES PROJETÉES peu- D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
vent blesser les yeux. D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
D Le soudage, le burinage, le passage de la pièce à état, ainsi que les pièces connexes.
la brosse métallique et le meulage provoquent D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
l’émission d’étincelles et de particules métalli-
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-
ques. Pendant leur refroidissement, les soudures risquent de projeter du
tion ou de branchement de la bouteille
laitier.
D Lire et suivre les instructions concernant les bouteilles de gaz compri-
D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le mé, les équipements associés et les publications P−1 de la CGA,
masque de soudage.
mentionnées dans les normes de sécurité.
OM-360 Page 6
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
OM-360 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna-
(téléphone : (305) 443−9353, site Web : www.aws.org). tional.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, norme American Welding Society AWS norme ANSI Z87.1, de l’American National Standards Institute, 11 West
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
33126 (téléphone : (305) 443−9353, site Web : www.aws.org). site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, norme NFPA 51B, de la National Fire Protection Association,
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé-
www.sparky.org). phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
OSHA, Occupational Safety and Health Standards for General Indus-
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Super-
site Web : www.cganet.com).
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca- 10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
nadian Standards Association, Standards Sales, 178 boulevard 353−2220, site Web : www.osha.gov).
OM-360 Page 8
SECTION 3 − INSTALLATION
3-1. Included with Your Unit
1 12 ft (3.7 m) Work Cable
With Clamp And
Quick-Connect
2 DB1712RDI 150 Amp TIG
Torch with 12 ft (3.7 m)
Cable
3 Electrode Holder and
7 Quick-Connect
4 Gas Hose
5 5 Gas Regulator
6 6 RFCS-14 Foot Control with
20 ft (6 m) Cable
4 7 8 ft (2.4 m) Primary Cord
Without Plug
. Some assembly is required.
For options and accessories see
back of book or contact your dis-
2 tributor.
1
3
803 253
18 in (460 18 in (460
mm) mm)
OM-360 Page 9
3-3. Dimensions And Weights
Dimensions
Height 30 in (762 mm)
A A 18 in (457 mm)
E C 1 in (25 mm)
C Weight
D
803 256 224 lbs (102 kg)
Front
3-4. Specifications
Rated Output at 40% Rated Input, Welding Amperage Max. Open-Circuit
Mode Duty Cycle 60 HZ, Single-Phase KVA KW Range Voltage
DC TIG 150 Amps at 16 Volts 208−230 V−45 A - (2)* 10.2 - (0.50)* 4.3 - (0.3)* 10−180 80
DC Stick 150 Amps at 26 Volts 208-230 V−47 A - (2)* 10.8 - (0.50)* 5.8 - (0.3)* 10−180 80
AC TIG 150 Amps at 16 Volts 208-230 V−54 A - (2)* 12.3 - (0.50)* 4.5 - (0.3)* 10−180 80
AC Stick 150 Amps at 26 Volts 208-230 V−54 A - (2)* 12.4 - (0.50)* 6 - (0.3)* 10−180 80
* () While idling.
OM-360 Page 10
3-6. 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.
50 50
DC TIG Max
40 40
Volts
Volts
20 20
AC Stick Min (Max DIG) AC Stick Max DC Stick Min (Min DIG) DC Stick Max
(Max DIG) (Max DIG)
10 10
AC Stick Min AC TIG Max
(Min DIG) (Max Pen) DC TIG Min
0 0
0 50 100 150 200 250 300 0 50 100 150 200 250 300
Amps
Amps
Weld Output
Terminals
Y Turn off power before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amperes
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
Work
Electrode 803 255
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D
OM-360 Page 11
3-8. Remote 14 Receptacle
A 24 volts DC.
OM-360 Page 12
3-10. Typical TIG Connections
Y Turn off power before mak-
ing connections.
1 Remote Foot Control
A customer supplied remote finger-
tip control may also be used.
6 2 Torch
3 Work Clamp
Connect remote control, torch, and
work clamp to receptacles as
5 shown.
7
4 Cylinder
Chain or secure cylinder to running
gear, wall, or other stationary
support.
5 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
6 Regulator/Flow Gauge
Install so face is vertical.
Tools Needed: 7 Flow Adjust
5/8, 1-1/8 in Typical flow rate is 20 cfh (cubic feet
per hour) (9.4 L/min).
4
NOTE: After activating remote con-
trol, 0.2 seconds of gas preflow will
begin.
Application:
Preflow is used to purge the imme-
diate weld area of atmosphere.
Preflow also aids in consistent arc
starting. Preflow is preset and is not
adjustable.
Application:
Postflow is required to cool tung-
sten and weld, and to prevent con-
tamination of tungsten and weld. In-
crease postflow time if tungsten or
weld are dark in appearance (see
Section 4-4).
OM-360 Page 13
3-11. Typical Stick Connections
Y Turn off power before mak-
ing connections.
1 Electrode Holder
2 Work Clamp
Connect electrode holder and work
clamp to receptacles as shown.
NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage
shown in table. If actual input voltage is outside of this range, damage to unit may
occur.
60 Hz Single Phase
Input Voltage 208-230
Input Amperes At Rated Output 54
Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1
Time-Delay 2 60
Normal Operating 3 80
Tools Needed:
OM-360 Page 15
SECTION 4 − OPERATION
4-1. Controls
5 6
208 414
1
OM-360 Page 16
4-2. Example of Front Panel Amperage Control For Stick (SMAW) Welding
Select amperage.
Select polarity.
or In Example:
For remote amperage control, front panel amperage control setting is the
maximum amperage available. Full range is 10−180 amps DC, but if front
panel amperage control is set at 130 amps, the range of remote amperage
control is 10 to 130 amps DC. NOTE: Remote amperage control is active
whenever a remote control is connected. If the remote device does not
include a means of controlling amperage through pin E (see Section 3-8),
the Amperage Adjustment control on the front panel remains active.
Connect remote control (see Section 3-10).
OM-360 Page 17
4-4. Postflow Control
To access postflow control, proceed as fol- version number clears meters). down. Postflow time does not change if out-
lows: The factory default setting is 12 seconds. To put is changed from DC to AC, or from AC
1 Output Selector Switch change the postflow time (5−18 seconds), to DC.
Place switch in the Electrode Positive posi- press and release the weld process button
Application:
tion. until desired time is displayed on the me-
ters. Press torch trigger or turn Off power to Postflow is required to cool tungsten and
2 Weld Process Switch save setting. weld, and to prevent contamination of tung-
3 Power Switch Use Postflow to set length of time gas flows sten and weld. Increase postflow time if
Press and hold Weld Process button while after welding stops. It is important to set tungsten or weld are dark in appearance
turning on the power. Hold button for enough time to allow gas to flow until after (approximately 1 second per 10 ampere of
approximately 7 seconds (or until software the tungsten and weld puddle has cooled welding current).
OM-360 Page 18
4-5. Selecting TIG Starting Characteristics
EN
-2-
Use this function to select desired TIG start- tions). Push and hold Weld Process button Press torch trigger or turn Off power to save
ing characteristics. and turn On power. Hold button for approxi- setting.
1 Output Selector Switch mately 7 seconds (or until software version Application:
number clears meters).
2 Weld Process Button Select 1 (light/soft start) − when welding at
The meters will display [AC] [−2−] or [E−] [2], de-
3 Power Switch low amperages on thin gauge material.
pending on position of Output Selector
4 Meters switch Select 2 (medium/normal start) − factory de-
To select or change TIG starting character- Press Weld Process button again to step fault setting used for most welding applica-
istics, proceed as follows: turn Off power. through the three start characteristics tions.
Place Output Selector switch in desired choices. Amperage (bottom) meter dis- Select 3 (high/hot start) − when welding at
position (each position, DCEN or AC has plays active choice 1= light start, 2=medium/ high amperages on thick materials with a
three applicable start characteristics op- normal start, 3=high/hot start. large diameter tungsten.
OM-360 Page 19
4-6. Timer/Cycle Counter
1 2 3
3
4 5 6
1 2 3
4
2
4 5 6
1 Output Selector Switch power on. seconds, and are read as 1, 234 hours
and 56 minutes.
2 Power Switch
3 Timer Display 4 Cycle Display
To read timer/cycle counter, place Output The cycles are displayed on the volt and
Selector switch between the AC and The hours and minutes are displayed on amp meters for the next five seconds,
Electrode Negative (−) position, then turn the volt and amp meters for the first five and are read as 123, 456 cycles.
OM-360 Page 20
4-7. Balance/DIG Control
1 Balance/DIG Control
Balance Control (AC GTAW):
Control changes the AC output
square wave. Rotating the control
1 towards 10 provides deeper pene-
tration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
Application:
When welding on oxide forming ma-
terials such as aluminum or magne-
sium, excess cleaning is not neces-
sary. To produce a good weld, only
Balance Control Examples a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
Setting Output Waveforms Arc
along the weld toes is required.
Balanced 50% Electrode Set control to 7 and adjust as nec-
Positive essary. Joint configuration, set-up,
process variables, and oxide thick-
50% Electrode
ness may affect setting.
0 Negative
NOTE: Arc rectification can occur
More Penetration when welding at high amperage
40% Electrode
Positive and/or while welding with helium
gas. If this condition occurs, in-
60% Electrode creasing the Balance control to-
10 Negative wards maximum penetration, may
help to restabilize the arc.
Ref. S-0795-A
OM-360 Page 21
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
. Maintain more often during severe conditions.
3 Months
6 Months
1 2
3
Tools Needed:
3
4 4
803 259
OM-360 Page 22
5-3. Voltmeter/Ammeter Help Displays
. All directions are in reference to the front 3 Help 3 Display 8 Help 8 Display
of the unit. All circuitry referred to is lo- Indicates the transformer of the unit has Not used.
cated inside the unit. There are no user overheated. The unit has shut down to allow
serviceable parts inside unit. the fan to cool it (see Section 3-5). Operation 9 Help 9 Display
will continue when the unit has cooled. Indicates a short in the thermal protection cir-
0 Help 0 Display 4 Help 4 Display cuitry located on the rectifier assembly of the
unit. If this display is shown, contact a Facto-
Indicates a short in the thermal protection cir- Indicates a malfunction in the thermal
ry Authorized Service Agent.
cuitry located on the transformer of the unit. protection circuitry located on the rectifier
If this display is shown, contact a Factory Au- assembly of the unit. If this display is shown, 10 Help 10 Display
thorized Service Agent. contact a Factory Authorized Service Agent.
Indicates Remote Output control is acti-
5 Help 5 Display vated. Release Remote Output control to
1 Help1 Display
Indicates the rectifier assembly of the unit clear help message.
An SCR overcurrent or undercurrent condi- has overheated. The unit has shut down to 11 Help 11 Display
tion has occurred. Turn power off and back allow the fan to cool it (see Section 3-5). Op-
on to correct condition. If problem continues, eration will continue when the unit has Indicates Output Selector switch is not in
contact a Factory Authorized Service Agent. cooled. correct position (see Section 4-1).
6 Help 6 Display 12 Help 12 Display
2 Help 2 Display
Not used. Indicates a non-allowable set-up on the front
Indicates a malfunction in the thermal 7 Help 7 Display panel.
protection circuitry located on the transform- 13 Help 13 Display
Not used.
er of the unit. If this display is shown, contact
a Factory Authorized Service Agent. Not used.
0 1 2 3 4
V V V V V
OM-360 Page 23
5-4. Troubleshooting
NOTE: The remedies listed below are recommendations only. If these remedies do not fix
the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 5-3 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble Remedy
No weld output; unit completely Place machine power switch in On position (see Section 4-1).
inoperative.
Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-7).
If using remote control, check position of Amperage Adjustment control (see Section 4-1).
No control of weld output. Make sure Amperage control is in proper position (see Section 4-1).
Lack of high frequency; difficulty in Select proper size tungsten.
starting GTAW arc.
Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
No weld output; fan does not run. Place line disconnect switch in On position (see Section 3-13).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-13).
No weld output; fan on. Be sure Polarity switch is not set between positions.
Fan not operating; weld output Check for and remove anything blocking fan movement.
available.
Have Factory Authorized Service Agent check fan motor.
OM-360 Page 24
SECTION 6 − ELECTRICAL DIAGRAM
207 214-C
Figure 6-1. Circuit Diagram All Models
OM-360 Page 25
SECTION 7 − HIGH FREQUENCY (HF)
7-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG high_freq 12/96 − S-0693
Weld Zone
11, 12
50 ft
(15 m)
10
9 14
8
13 2
4 5 6
S-0694
OM-360 Page 26
7-3. Correct Installation
Weld Zone 6
50 ft
(15 m) 50 ft
(15 m)
1
5
2
7
7 Ground All
Metal Objects
And All Wiring
In Welding Zone
Using #12 AWG
Wire Ground
Workpiece
If Required
By Codes 8
Nonmetal
Building
7
7
10
Metal Building
9
1 HF Source (Welder With Built-In HF Or Electrically join (bond) all conduit sections 8 Metal Building Panel Bonding Methods
Separate HF Unit) using copper straps or braided wire. Ground
conduit every 50 ft (15 m). Bolt or weld building panels together, install
Ground metal machine case, work output copper straps or braided wire across seams,
terminal, line disconnect device, input 5 Water Pipes And Fixtures and ground frame.
supply, and worktable.
Ground water pipes every 50 ft (15 m). 9 Windows And Doorways
2 Welding Zone And Centerpoint
6 External Power Or Telephone Lines Cover all windows and doorways with
A circle 50 ft (15 m) from centerpoint
grounded copper screen of not more than
between HF source and welding torch in all Locate HF source at least 50 ft (15 m) away 1/4 in (6.4 mm) mesh.
directions. from power and phone lines.
3 Weld Output Cables 10 Overhead Door Track
7 Grounding Rod
Keep cables short and close together. Ground the track.
Consult the National Electrical Code for
4 Conduit Joint Bonding And Grounding specifications.
OM-360 Page 27
SECTION 8 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2000
Y Whenever possible and practical, use DC weld output instead of AC weld output.
8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended.
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
OM-360 Page 28
8-2. Preparing Tungsten Electrode For Welding
Y 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-
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
1 Tungsten Electrode
1 2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1 Stable Arc
1
2 Flat
2 Diameter of this flat determines
amperage capacity.
3 3 Grinding Wheel
Grinding wheel should be dedi-
cated to grinding tungsten only.
4 Straight Ground
4
1 Arc Wander
1
2 Point
3 Grinding Wheel
2 Grinding wheel should be dedi-
cated to grinding tungsten only.
4 Radial Ground
3
1 Tungsten Electrode
2 Balled End
Y Understand and follow
safety symbols at start of
1 Section 9-1 before preparing
tungsten.
Ball end of tungsten by applying AC
amperage recommended for a giv-
1 − 1-1/2 Times en electrode diameter (see Section
Electrode Diameter 8-1). Let ball on end of the tungsten
take its own shape.
OM-360 Page 29
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW)
1/16 in
3/16 in
Bottom View Of Gas Cup
OM-360 Page 30
9-2. Torch Movement During Welding
Tungsten Without Filler Rod
75° 15°
Welding direction
OM-360 Page 31
9-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
75°
15°
10°
20-40°
Lap Joint
75°
15°
30°
90°
Corner Joint
75°
15°
OM-360 Page 32
SECTION 10 − STICK WELDING (SMAW) GUIDELINES
Tools Needed:
OM-360 Page 33
10-2. Electrode and Amperage Selection Chart
AMPERAGE
RANGE
ELECTRODE
DIAMETER
100
150
200
250
300
350
400
450
PENETRATION
50
ELECTRODE
POSITION
USAGE
3/32
DC*
AC
1/8
6010
5/32
& 3/16
6011 7/32
1/4 6010 EP ALL DEEP MIN. PREP, ROUGH
1/16 HIGH SPATTER
6011 EP ALL DEEP
5/64
3/32 6013 EP,EN ALL LOW GENERAL
1/8 SMOOTH, EASY,
6013 7014 EP,EN ALL MED FAST
5/32
3/16 LOW HYDROGEN,
7018 EP ALL LOW STRONG
7/32
1/4 FLAT
7024 EP,EN HORIZ LOW SMOOTH, EASY,
3/32 FASTER
FILLET
1/8
5/32 NI-CL EP ALL LOW CAST IRON
7014
3/16 308L EP ALL LOW STAINLESS
7/32 *EP = ELECTRODE POSITIVE (REVERSE POLARITY)
1/4 EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
3/32
1/8
5/32
7018
3/16
7/32
1/4
3/32
1/8
5/32
7024
3/16
7/32
1/4
3/32
1/8
Ni-Cl
5/32
3/16
3/32
308L 1/8
5/32
Ref. S-087 985-A
S-0050
OM-360 Page 34
10-5. Positioning Electrode Holder
10°-30°
90° 90°
GROOVE WELDS
10°-30°
45°
45°
2 3 4
5 S-0053-A
S-0052-B
OM-360 Page 35
10-8. Conditions That Affect Weld Bead Shape
NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Correct Angle
Angle Too Small 10° - 30° Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
NOTE Normally, a 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.
S-0054-A
OM-360 Page 36
10-10. Butt Joints
1 1 Tack Welds
Prevent edges of joint from drawing
2 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
30° Good for materials 3/16 − 3/4 in
1/16 in (5-19 mm) thick. Cut bevel with oxy-
(1.6 mm) acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
3 4 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).
S-0662
3
S-0060 / S-0058-A / S-0061
OM-360 Page 37
10-13. Weld Test
1 Vise
3 2 Weld Joint
3 Hammer
Strike weld joint in direction shown.
3 A good weld bends over but does
not break.
2 To 3 in
(51-76 mm)
2 To 3 in
(51-76 mm)
2 2
1/4 in
(6.4 mm) 1 1
S-0057-B
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
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-360 Page 38
10-16. Troubleshooting − Incomplete Fusion
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.
Momentarily hold arc on groove side walls when using weaving technique.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
OM-360 Page 39
10-19. Troubleshooting − Burn-Through
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
OM-360 Page 40
Notes
OM-360 Page 41
SECTION 11 − PARTS LIST
7
6
9 8
5
10
4
3
17
1 11 16
15
12
28 13
2
14
18
19 1
22 20
23
24
21
28
27
25 29
26
30
31
32
36
37 35
34
38 33
803 252-B
. . . 1 . . . . . . . . . . 208412 . . . . . PANEL,SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . 208435 . . . . . BAFFLE,FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 208874 . . . . . SUPPORT,LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 026627 . . . . . GASKET,LIFTING EYE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 203990 . . . . . LABEL,WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . +208409 . . . . . COVER,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 201019 . . . . . LABEL,WARNING ELECTRIC SHOCK EXCESS WEIGHT . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 204389 . . . . . HOLDER,TORCH/CABLE (CONSISTING OF) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 200922 . . . . . . . . HOUSING, TORCH CABLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 200920 . . . . . . . . DOOR, TORCH CABLE HOLDER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 208892 . . . . . FAN,AC 230V BRUSHLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . C1 . . 191944 . . . . . CAPACITOR,POLYP MET FILM .10UF 250VAC 10% . . . . . . . . . . . . . . . . 1
. . . 13 . . . . R2 . . 189132 . . . . . RESISTOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . R1 . . 220808 . . . . . RESISTOR,WW FXD 100 W 50 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . +208410 . . . . . PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 604102 . . . . . CONN,CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 190442 . . . . . CORD SET,250V 8GA 3/C 10FT ST JKT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 185759 . . . . . LABEL,WARNING ELECTRIC SHOCK & INPUT POWER . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 137761 . . . . . NUT, 750NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . GS . . 216607 . . . . . VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 209328 . . . . . HOSE,NPRN BRD NO 1 X .250 ID X 19.500 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 089120 . . . . . CLAMP,HOSE .375 − .450 CLP DIA SLFTTNG GREEN . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 208294 . . . . . CONNECTOR,FASTON MALE 4−PRONG . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 207560 . . . . . INSULATOR, STANDOFF W/STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . C14 . . 206878 . . . . . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . T1,Z1 . . 211260 . . . . . TRANSFORMER/STABILIZER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . TH1 . . 201 443 . . . . . Thermistor, NTC 10k ohm @ 25 deg C 27.5 in lead . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . Fig.11-3 . . . . . RECTIFIER ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 194591 . . . . . LABEL,MILLER 9.776 X 4.126 HORIZONTAL SYNCROWAV . . . . . . . . . 2
. . . 29 . . . . . . . . . . 208436 . . . . . HF BOX, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . R8 . . . 211261 . . . . . RESISTOR,WW FXD 100 W 200 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . T4 . . 208890 . . . . . COIL,COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . G1 . . 199854 . . . . . SPARK GAP ASSY, (CONSISTING OF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 199855 . . . . . . . . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 199856 . . . . . . . . HOLDER, POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . 196455 . . . . . . . . POINTS, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . C18 . . 195552 . . . . . CAPACITOR,POLYP MET FILM 20. UF 250 VAC 10% . . . . . . . . . . . . . . . 1
. . . 34 . . . . C3 . . 215779 . . . . . CAPACITOR, MICA .002 UF 10000 V PANEL MTG W/LEA . . . . . . . . . . . 1
. . . 35 . . . . T3 . . 208045 . . . . . XFMR,HIGH VOLTAGE 115V PRI 3600V SEC 30 MA W/TERM . . . . . . . 1
. . . 36 . . . . . . . . . +208413 . . . . . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . 192828 . . . . . LABEL,WARNING ELECTRICAL SHOCK ETC . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . Fig.11-2 . . . . . FRONT PANEL, WITH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG1 . . 202119 . . . . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG7 . . 202116 . . . . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG8 . . 202117 . . . . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG11 . . 202118 . . . . . CONNECTOR W/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-360 Page 43
Item Dia. Part
No. Mkgs. No. Description Quantity
+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-360 Page 44
. Hardware is common and 7
not available unless listed. 6 8
3 5
2 4
1 12
17 10
16
15
14 18
11
12
13 11 803 257-B
Figure 11-2. Panel, Front With Components (Fig 11-1 Item 38)
+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-360 Page 45
1 . Hardware is common and
not available unless listed.
7 6
803 258
208 887 Figure 11-3. Rectifier Assembly (Fig 11-1 item 27)
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-360 Page 46
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
for your local the effective date of this limited warranty is free of defects in * Remote Controls
material and workmanship at the time it is shipped by Miller.
Miller distributor. * Accessory Kits
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such
* Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue Limited Warranty shall not apply to:
Service writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear. (Exception:
need. Most replacement Miller shall honor warranty claims on warranted equipment brushes, slip rings, and relays are covered on Bobcat,
parts can be in your listed below in the event of such a failure within the warranty Trailblazer, and Legend models.)
time periods. All warranty time periods start on the date that the
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others,
Support year after the equipment is sent to a North American distributor such as engines or trade accessories. These items are
Need fast answers to the or eighteen months after the equipment is sent to an covered by the manufacturer’s warranty, if any.
International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
Contact your distributor. 1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
distributor and Miller is standards, or equipment which has not had reasonable
* Inverters (input and output rectifiers only) and necessary maintenance, or equipment which has
there to help you, every
step of the way. 2. 3 Years — Parts and Labor been used for operation outside of the specifications for the
equipment.
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Semi-Automatic and Automatic Wire Feeders PERSONS TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated) In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Maxstar 150 replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods at
3. 1 Year — Parts and Labor Unless Specified customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
* Motor Driven Guns (w/exception of Spoolmate Miller. Therefore no compensation or reimbursement for
Spoolguns) transportation costs of any kind will be allowed.
* Process Controllers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Positioners and Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources and Coolers
ANY OTHER LEGAL THEORY.
* Water Coolant Systems (Non-Integrated)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Flowgauge and Flowmeter Regulators (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* HF Units REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Maxstar 85, 140 PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Spot Welders OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Load Banks MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Arc Stud Power Sources & Arc Stud Guns PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Racks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
Models)
special or consequential damages, so the above limitation or
* Field Options exclusion may not apply to you. This warranty provides specific
(NOTE: Field options are covered under True legal rights, and other rights may be available, but may vary
Blue for the remaining warranty period of the from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may be
* MIG Guns/TIG Torches available, but may vary from province to province.
miller_warr 6/04
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
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.