Owners ManualandOperation Guide

HIGH FREQUENCY ARCSTABILIZER

811-363-000

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TABLE OF CONTENTS

TABLE OF CONTENTS ................................................................................................................................ 2IMPORTANT SAFETY INSTRUCTIONS ....................................................................................................... 3SHOCK HAZARDS ...................................................................................................................................... 3FLASH HAZARDS ....................................................................................................................................... 4FIRE HAZARDS ........................................................................................................................................... 4FUME HAZARDS ......................................................................................................................................... 5COMPRESSED GASSES AND EQUIPMENT HAZARDS ........................................................................... 5ADDITIONAL SAFETY INFORMATION ....................................................................................................... 6

PRODUCT DESCRIPTION ............................................................................................................................ 7SPECIFICATIONS ....................................................................................................................................... 7DUTY CYCLE .............................................................................................................................................. 7PROVIDE REQUIRED POWER .................................................................................................................. 8POWER REQUIREMENTS........................................................................................................................ 8

SPECIAL CONSIDERATIONS REGARDING HIGH FREQUENCY ENERGY ............................................ 8INSTALLATION AND ASSEMBLY ................................................................................................................ 8INSTALLATION CONSIDERATIONS ........................................................................................................... 8SHIELDING AND GROUNDING THE AREA ............................................................................................... 9CONNECT UNIT TO POWER SOURCE ..................................................................................................... 9CONNECTION TO YOUR WELDING POWER SUPPLY ............................................................................ 9CONNECTION OF WELDING OUTPUT LEADS......................................................................................... 9

MAINTENANCE AND TROUBLESHOOTING ............................................................................................ 10MANUFACTURER’S LIMITED WARRANTY ............................................................................................... 11

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IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS! DONOT OPERATE YOUR WELDERUNTIL YOU HAVE READ AND

UNDERSTAND THESEINSTRUCTIONS!

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 CAUSEDISCOMFORT, ILLNESS, AND DEATH!IMPROPER HANDLING AND MAINTENANCE OFCOMPRESSED GAS CYLINDERS ANDREGULATORS CAN RESULT IN SERIOUS INJURYOR DEATH!IMPORTANT! DO NOT ATTEMPT OPERATION ofthis welding equipment until reading andunderstanding the following safety instructions toreduce risk of DEATH, INJURY, AND PROPERTYDAMAGE.

SHOCK HAZARDS

ELECTRIC SHOCK CAN KILL! To reduce risk ofdeath from electric shock, read, understand, and followthe following safety instructions. In addition, makecertain that anyone else who uses this weldingequipment or is a bystander in the welding areaunderstand and follow these safety instructions aswell.

HIGH FREQUENCY RADIATIONElectrical equipment utilizing high frequencyenergy in any way is capable of radiating electricalinterference. Read and follow instructions givenlater in this manual to make sure installation issuch that interference is minimized.Wearers of heart pacemakers and other electronicequipment vital to life should check with the lifesupport manufacturer and their physician todetermine if a hazard exists.Protect hands and all body parts that may come incontact with the welding circuit. High frequency energycan cause painful burns.

NEVER Stand, Sit, Lie, Lean On, Touch, or come intophysical contact in any way with any part of thewelding current circuit including:

the work piece or any conductive material incontact with it, the ground clamp, the electrode,any metal parts on the electrode holder or TIGtorch

NEVER weld in a damp area or come in contact with amoist or wet surface when welding.

NEVER attempt to weld if any part of clothing or bodyis wet.

NEVER allow the welding equipment to come incontact with water or moisture.

NEVER drag welding cables (or TIG torch assembly)or welder power cord through or allow them to comeinto 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 partof body or clothing is wet or damp, or if standing in orin physical contact of any kind with water or moisture.

NEVER connect welder ground clamp to or weld onelectrical conduit.

NEVER alter power cord or power cord plug in anyway.

NEVER attempt to plug welder into power source ifground prong on power cord plug is bent over, broken,or missing.

NEVER allow welder to be connected to a powersource or attempt to weld if welder, welding cables (orTIG torch assembly), welding site, or welder powercord are exposed to rain, snow, sleet, mist, fog orother forms of atmospheric precipitation, or mist orspray 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 pluggedinto the welder.

NEVER modify any wiring, ground connections,switches, or fuses in this welding equipment.

ALWAYS wear welding gloves to help insulate handsfrom welding circuit.

ALWAYS keep containers of water or other liquids farenough away from welder and work area so that ifspilled, the liquid could not possibly come in contactwith the welder, welding cables (or TIG torchassembly), welder power cord, the work piece beingwelded, or any other part of the electrical weldingcircuit.

ALWAYS replace any cracked or damaged parts thatare insulated or act as insulators such as weldingcables (or TIG torch assembly), power cord, orelectrode holder IMMEDIATELY.

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FLASH HAZARDS

ARC RAYS CAN INJURE EYES AND BURN SKIN!To reduce risk of injury from arc rays, read,understand, and follow the following safetyinstructions. In addition, make certain that anyone elsethat uses this welding equipment, or is a bystander inthe welding area, understands and follows thesesafety instructions as well.

NEVER look at an electric arc without properprotection. A welding arc is extremely bright andintense and, with inadequate or no eye protection, theretina can be burned, leaving a permanent dark spot inthe field of vision. A shield or helmet with a number 10shade filter lens (minimum) must be used.

NEVER strike a welding arc until all bystanders andyou (the welder) have welding shields and/or helmetsin place.

NEVER wear a cracked or broken helmet and replaceany cracked or broken filter lenses IMMEDIATELY.

NEVER allow the uninsulated portion of the electrodeholder to touch the ground clamp or grounded work toprevent an arc flash from being created on contact.

ALWAYS provide bystanders with shields or helmetsfitted with a #10 shade filter lens.

ALWAYS wear protective clothing. The intense light ofthe welding arc can burn the skin in much the sameway as the sun, even through light-weight clothing.Wear dark clothing of heavy material. The shirt wornshould be long sleeved and the collar kept buttoned toprotect chest and neck.

ALWAYS protect against REFLECTED ARC RAYS.Arc rays can be reflected off shiny surfaces such as aglossy painted surface, aluminum, stainless steel, andglass. It is possible for your eyes to be injured byreflected arc rays even when wearing a protectivehelmet or shield. If welding with a reflective surfacebehind you, arc rays can “bounce off” the surface, thenoff the filter lens on the inside of your helmet or shield,then into your eyes. If a reflective background exists inyour welding area, either remove it or cover it withsomething nonflammable and non-reflective. Reflectedarc rays can also cause skin burn in addition to eyeinjury.

FIRE HAZARDS

FIRE OR EXPLOSION CAN CAUSE DEATH,INJURY, AND PROPERTY DAMAGE! To reduce riskof death, injury, or property damage from fire orexplosion, read, understand, and follow the followingsafety instructions. In addition, make certain thatanyone else that uses this welding equipment, or is abystander in the welding area, understand and followthese safety instructions as well. REMEMBER! Arcwelding by nature produces sparks, hot spatter, moltenmetal drops, hot slag, and hot metal parts which canstart 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 andcleared of combustible and/or flammable materials. BEAWARE that sparks and slag can fly 35 feet and canpass through small cracks and openings. If work andcombustibles cannot be separated by a minimum of 35feet, protect against ignition with suitable, snug-fitting,fire resistant covers or shields.

NEVER weld on walls until checking for and removingcombustibles touching the wall on the other side.

NEVER weld, cut, or perform other hot work on usedbarrels, drums, tanks, or other containers thatcontained a flammable or toxic substance. Thetechniques for removing flammable substances andvapors in order to make a used container safe forwelding or cutting are quite complex and requirespecial education and training.

NEVER strike an arc on a compressed gas or aircylinder or other pressure vessel. Doing so will createa brittle area that can result in a violent ruptureimmediately or at a later time as a result of roughhandling.

NEVER weld or cut in an area where the air maycontain flammable dust (such as grain dust), gas, orliquid vapors (such as gasoline).

NEVER handle hot metal, such as the work piece orelectrode 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 protectiveclothing such as leather jacket or sleeves, fire resistantleggings, or apron. Hot sparks or metal can lodge inrolled up sleeves, trouser cuffs, or pockets. Sleevesand collars should be kept buttoned and pocketseliminated from the front.

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ALWAYS have a fire extinguishing equipment handyfor instant use! A portable chemical fire extinguisher,type ABC, is recommended.

ALWAYS wear ear plugs when welding overhead toprevent 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 floorswith heat resistant covers or shields.

ALWAYS check welding area to make sure it is free ofsparks, glowing metal or slag, and flames beforeleaving the welding area.

FUME HAZARDS

FUMES, GASSES, AND VAPORS CAN CAUSEDISCOMFORT, ILLNESS, AND DEATH! To reducerisk of discomfort, illness, or death, read, understand,and follow the following safety instructions. In addition,make certain that anyone else that uses this weldingequipment or is a bystander in the welding area,understands and follows these safety instructions aswell.

NEVER weld in an area until it has been checked foradequate ventilation as described in ANSI standard#Z49.1. If ventilation is not adequate to exchange allfumes and gasses generated during the weldingprocess with fresh air, do not weld unless you (thewelder) and all bystanders are wearing air-suppliedrespirators.

NEVER heat metals coated with or containingmaterials that produce toxic fumes, such asgalvanized steel, unless the coating is removed, thearea is well ventilated, or the operator and allbystanders wear air-supplied respirators.

NEVER weld, cut, or heat lead, zinc, cadmium,mercury, beryllium, or similar metals without seekingprofessional advise and inspection of the ventilation ofthe welding area. These metals produce EXTREMELYTOXIC fumes which can cause discomfort, illness, anddeath.

NEVER weld or cut in areas that are near chlorinatedsolvents. Vapors from chlorinated hydrocarbons, suchas trichloroethylene and perchloroethylene, can bedecomposed by the heat of an electric arc or itsultraviolet radiation to form PHOSGENE, a HIGHLYTOXIC gas, along with other lung and eye-irritatinggasses. Do not weld or cut where these solvent vaporscan be drawn into the work area or where theultraviolet radiation can penetrate to areas containingeven very small amounts of these vapors.

NEVER weld in a confined area unless it is beingventilated or the operator (and anyone else in thearea) 4 wearing an air-supplied respirator.

NEVER bring gas cylinders into or allow gas leaks in aconfined space. Leaked gas can rapidly reduceoxygen concentration levels in a confined space.

ALWAYS shut off shielding gas supply at its sourcebefore leaving a confined area and check to makesure the area is safe before reentering it.

ALWAYS stop welding if you develop momentary eye,nose, or throat irritation as this indicates inadequateventilation. Stop work and take necessary steps toimprove ventilation in the welding area. Do not resumewelding if physical discomfort persists.

COMPRESSED GASSES ANDEQUIPMENT HAZARDS

IMPROPER HANDLING AND MAINTENANCE OFCOMPRESSED GAS CYLINDERS ANDREGULATORS CAN RESULT IN SERIOUS INJURYOR DEATH! To reduce risk of injury or death fromcompressed gasses and equipment hazards, read,understand, and follow the following safetyinstructions. In addition, make certain that anyone elsewho uses this welding equipment or is a bystander inthe welding area understands and follows these safetyinstructions as well.

NEVER use flammable gasses with TIG welders. Onlyinert or non-flammable gasses are suitable for TIGwelding. Examples are Carbon Dioxide, Argon,Helium, etc. or mixtures of more than one of thesegasses.

NEVER attempt to mix gasses in or refill a cylinderyourself.

NEVER expose cylinders to excessive heat, sparks,slag, and flame, etc. Cylinders exposed totemperatures above 130 degrees F. will require waterspray cooling.

NEVER expose cylinders to electricity of any kind.

NEVER use cylinder or its contents for other than itsintended use. Do not use as a support or roller.

NEVER locate cylinders in passageways or workareas where they may be struck.

NEVER lift cylinders off the ground by their valves orcaps or with chains, slings, or magnets.

NEVER use a wrench or hammer to open a cylindervalve that cannot be opened by hand. Notify yoursupplier.

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NEVER modify or exchange gas cylinder fittings.

NEVER deface or alter name, number, or othermarkings on a cylinder. It is illegal and hazardous.

NEVER use cylinders without the name of the gasmarked on the cylinder. Do not rely on cylinder color toidentify the content.

NEVER connect a regulator to a cylinder containinggas other than that for which the regulator wasdesigned.

NEVER attempt to make regulator repairs. Send faultyregulators for repair to manufacturer’s designatedrepair center.

NEVER attempt to lubricate regulator.

ALWAYS handle cylinders carefully to prevent leaksand damage to their walls, valves, or safety devices.

ALWAYS secure cylinders with a steel chain so thatthey cannot be knocked over.

ALWAYS protect cylinder, especially valve, frombumps, 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 serviceimmediately for repair (first close cylinder valve) if anyof the following occur:

Gas leaks externally, delivery pressure continuesto rise with down steam valve closed, and/orgauge pointer does not move off the stop pinwhen pressurized or fails to return to the stop pinafter pressure is released.

ADDITIONAL SAFETYINFORMATION

For additional information concerning welding safety,refer to the following standards and comply with asapplicable.

• ANSI Standard Z49.1 — SAFETY IN WELDINGAND CUTTING — obtainable from the AmericanWelding Society, 550 NW Le Jeune Road, Miami, FL33126 Telephone (800) 443-9353, Fax (305) 443-7559 — www.amweld.org or www.aws.org

• ANSI Standard Z87.1 — SAFE PRACTICE FOROCCUPATION AND EDUCATIONAL EYE ANDFACE PROTECTION — obtainable from theAmerican 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 WELDINGPROCESS — obtainable from the National FireProtection 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 OFCOMPRESSED 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 — obtainablefrom your state OSHA office or U. S. Dept. of LaborOSHA, Office of Public Affairs, Room N3647, 200Constitution Ave. Washington, DC 20210 —www.osha.gov

• CSA Standard W117.2 — Code for SAFETY INWELDING AND CUTTING. — obtainable fromCanadian Standards Association, 178 Rexdale Blvd.Etobicoke, Ontario M9W 1R3 — www.csa.ca

• American Welding Society Standard A6.0.WELDING AND CUTTING CONTAINERS WHICHHAVE HELD COMBUSTIBLES. — obtainable fromthe American Welding Society, 550 NW Le JeuneRoad, Miami, FL 33126 Telephone (800) 443-9353,Fax (305) 443-7559 — www.amweld.org orwww.aws.org

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PRODUCT DESCRIPTION

Your High Frequency Arc Stabilizer is designed for usein either AC or DC shielded metal arc welding(SMAW), otherwise known as stick welding. It is alsoused as pan of a Tungsten Inert Gas (GTAW, TIG orHeliarc) welding setup.

The High Frequency Arc Stabilizer is a supplement tothe standard arc welding power supply.

It consists of a spark gap type oscillator whichsuperimposes high frequency energy onto the weldingcurrent by means of an air core coupling transformer.The secondary of the air core transformer is in serieswith the arc current and carries the full welding current.

There are several benefits to adding high frequency tothe welding output:

1. The welding arc may be started without touchingthe electrode to the work piece.

2. Better arc stability and arc cleaning action isobtained.

3. A longer arc is possible - this is particularly usefulwith some types of welding rods.

4. Welding electrodes have longer life becausetouch starting is eliminated.

5. A wider range of welding current can be used forany specific welding electrode.

6. When used with a Tungsten Inert Gas (TIG,GTAW) Torch, aluminum and magnesium may bewelded with ease.

SPECIFICATIONSPrimary 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 electricwelding power supplies ONLY! It shouldnot be used with an engine driven weldinggenerator unit. The frequencies generatedwithin the High Frequency Arc Stabilizerwill not synchronize properly with theoutput of an AC welding generator.

DUTY CYCLEThe duty cycle rating of a unit tells the operator howlong he or she can weld and how long the unit mustrest and cool. It is expressed as a percentage of 10minutes (the industry recognized cycle time) andrepresents the maximum welding time allowed, withthe 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 unitmay require derating of the welding power supply.Consult the manufacturer of the power supply to verifythe duty cycle of the power supply when used with ahigh frequency unit. Typically the duty cycle is reducedby 1/3rd when used in this manner.

Duty CycleRating

MaximumWelding Time

RequiredResting Time

20%40%60%80%

100%

2 Minutes4 Minutes6 Minutes8 Minutes

10 Minutes

8 Minutes6 Minutes4 Minutes2 Minutes0 Minutes

DO NOT CONSTANTLY EXCEED THE DUTY CYCLEOR DAMAGE TO THIS HIGH FREQUENCY UNITWILL RESULT!

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INSTALLATION AND ASSEMBLY

PROVIDE REQUIRED POWER

POWER REQUIREMENTSDO NOT OPERATE THIS UNIT if the ACTUAL powersource voltage is less than 105 volts AC or greaterthan 132 volts AC. Contact a qualified electrician if thisproblem exists. Improper performance and/or damageto the unit will result if operated on inadequate orexcessive power.

ELECTRIC SHOCK CAN KILL! FIRE CAN KILL,INJURE, AND CAUSE PROPERTY DAMAGE! Toreduce the risk of electric shock and fire, connect onlyto properly grounded and fused outlets. NEVERALTER the AC power cord or power cord plugprovided on the unit. NEVER ALTER an extensioncord or extension cord plugs.

SPECIAL CONSIDERATIONSREGARDING HIGH

FREQUENCY ENERGYElectrical equipment utilizing high frequencyenergy in any way is capable of radiating electricalinterference. Read and follow instructions givenlater in this manual to make sure installation issuch that interference is minimized.Wearers of heart pacemakers and other electronicequipment vital to life should check with the lifesupport manufacturer and their physician todetermine if a hazard exists.Protect hands and all body parts that may come incontact with the welding circuit. High frequency energycan cause painful burns.

High frequency energy has certain undesirablecharacteristics which should be eliminated orminimized when welding. Any equipment utilizing highfrequency energy in any way is capable of radiatinginterference if not properly installed. Since the highfrequency unit is a basic type of radio transmitter, itmay cause interference with the reception of nearbyradio and television receivers as well as superimposeelectronic pulses in solid state devices nearby.Therefore, protection must be provided to stop leakageof the high frequency energy as much as possible.

In High Frequency Arc Stabilizer applications,interfering radiation can escape in four distinctmethods:

1. Direct Radiation from the Welding MachineThis is radiation that escapes directly from the welding

machine case. It may be very noticeable if the unit isnot fully assembled with all cabinet screws secured orif the unit is not properly grounded.

This unit is adequately shielded to prevent directradiation of noticeable consequence assuming it isproperly grounded.

2. Direct Feed-Back to Power LineHigh frequency energy may get into the power line bydirect coupling inside the welder or the high frequencyunit. The power line then acts as an antenna, emittingthe high frequencies.

By using proper shielding techniques given below, thiscan be prevented.

3. Direct Radiation from the Welding LeadsDirect radiation from the welding leads, while verypronounced, decreases rapidly with distance from theleads themselves. Using as short of a welding lead setas possible, you can reduce the interference greatly.

The intensity and frequency of the radiation can bealtered over wide ranges by simply changing thelocations and positions of the welding leads and thework. Keeping the work and ground leads closetogether and unlooped can help a great deal.

4. Pick-Up and Radiation from Power LinesEven though welding lead radiation falls off rapidly withdistance, the field strength in the immediate vicinity ofthe welding area may be extremely high. Unshieldedwiring and ungrounded metallic objects in this strongfield area may pick up the direct radiation, conduct theenergy for some distance, and produce a stronginterference in another area.

This is usually the most troublesome source ofinterference, but careful adherence to the shieldingand grounding instructions given below will minimizethe problem.

INSTALLATIONCONSIDERATIONS

To minimize the effects of high frequency energyradiating out of the welding area, it is important toprovide shielding to the electrical wiring and otherconductive items in the welding area. A zone ofapproximately 50 feet around, above, and below theweld area is susceptible to high frequency generatedby the unit and the arc. Listed below are guidelines inpreparing the weld area and the building.

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SHIELDING AND GROUNDINGTHE AREA

All building wiring within 50 feet of the welding areashould be shielded with solid metallic conduit. The useof helically wrapped metal conduit is not sufficient toeffectively shield the wiring. Only solid conduit shouldbe used and care should be taken to insure thatconnections at connection points of the conduit aregood. A good suggestion is to use copper strap acrossconnection points of the conduit to make the groundcomplete.

The ground of the primary power system must be atleast 8 feet into moist soil and should be connected tothe shielding conduit with as short as possible of aconnecting wire.

When welding in a metal building, it is important thatthe building itself be properly grounded. Welding withina metal building does not improve or detract from thehigh frequency energy radiated from the weld area.

NOTE: All changes in power and lighting wiringshould be made by qualified personnelonly and be done in accordance with theNational Electrical Code as well as anylocal codes and requirements.

CONNECT UNIT TO POWERSOURCE

1. DO NOT ALTER the AC power cord or powercordplug on this unit. Doing so may VOID THEWARRANTY. If the unit’s AC power cord plugdoes not mate with your existing receptacle, havean appropriate receptacle installed by a qualifiedelectrician in accordance with the NationalElectrical Code and local codes and ordinances.Do not use any adapters between the unit’s ACpower cord plug and AC power source receptacle.

2. Make sure the POWER SWITCH on the front ofthe unit is turned to its “OFF” position. Then plugthe unit’s power cord plug into the AC powersource receptacle.

CONNECTION TO YOURWELDING POWER SUPPLY

There are two leads coming from the front of the HighFrequency Arc Stabilizer. These are the welding powerinput leads. They are placed into the matingreceptacles on the front of your welding power supply.The lead marked “TO WELDER GROUND” is placedinto the ground jack of the welder, the lead marked“TO WELDER OUTPUT” is placed in the output jack ofthe welder.

When welding with DC current, select the polarity withthese leads by placing the cables as shown in thefollowing chart:

DC Straight DC ReversePolarity Polarity

Connect “TO WELDER Connect “TO WELDERGROUND” to the Welder’s GROUND” to the Welder’s

Positive Output Negative Output

Connect “TO WELDER Connect “TO WELDEROUTPUT” to the Welder’s OUTPUT” to the Welder’s

Negative Output Positive Output

If your welding power supply does not have plug-instyle output jacks, obtain part number 2806, AdapterFitting Kit, to adapt your existing welder output cablesfor use with this unit. See your dealer for details.

CONNECTION OF WELDINGOUTPUT LEADS

Always place the electrode of the welding circuit in theoutput receptacle marked “TO TIG TORCH” even if notusing a TIG Torch. The ground cable is always placedin the receptacle marked “TO WORK GROUND”.

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MAINTENANCE AND TROUBLESHOOTING

The spark gaps inside the High Frequency ArcStabilizer have been pre-set at the factory. Duringoperation, this spark gap setting will gradually increasedue to erosion of the spark gap contacts. The sparkgap should be checked and readjusted after every 200hours of operation. Variations in spark gap distancecan lead to excessive high frequency radiation beingemitted.

WARNING: High voltage is present inside the unitwhen plugged in. Unplug unit before servicing!

To adjust the spark gap:

1. Remove the cover of the cabinet.

2. Loosen the set screws that hold the two outsidecontacts.

3. The spark gap should be set at .007-.008". Use a.007 feeler gauge and insert between thecontacts.

4. Push the end contacts (one at a time) toward thecenter fixed contact until the gaps between thecontacts are the against the feeler gauge.

5. Tighten the set screws securely and recheck thegap, making sure that the .007" feeler will slidethrough, but a .009" gauge will not.

6. Clean dust, dirt, grease, etc. from your unit. Air-blow any dust and dirt that may have accumulatedinside.

7. Reinstall the cover.

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MANUFACTURER’S LIMITED WARRANTY

The manufacturer warrants that for 1 year from date ofpurchase , it will repair, at no charge for parts or labor,the High Frequency Arc Stabilizer proven defective inmaterial or workmanship. If after reasonable efforts bythe manufacturer, the unit is deemed unrepairable, themanufacturer will, at its option, refund the originalpurchase price or supply a replacement unit.

THE TERMS OF THE MANUFACTURER’S LIMITEDWARRANTY CONSTITUTE THE BUYER’S SOLEAND EXCLUSIVE REMEDY. THE IMPLIEDWARRANTIES OR MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE ARELIMITED IN DURATION TO THIS EXPRESSWARRANTY. AFTER 1 YEAR FROM DATE OFPURCHASE FOR UNIT, ALL RISK OF LOSS, FROMWHATEVER REASON, SHALL BE UPON THEPURCHASER.

THE MANUFACTURER SHALL NOT BE LIABLE FORINCIDENTAL AND CONSEQUENTIAL DAMAGESUNDER ANY CIRCUMSTANCES: THEMANUFACTURER’S LIABILITY, IF ANY, SHALLNEVER EXCEED THE PURCHASE PRICE OF THISPRODUCT, REGARDLESS OF WHETHER LIABILITYIS PREDICATED UPON BREACH OF WARRANTY(EXPRESSED OR IMPLIED), NEGLIGENCE, STRICTTORT OR ANY OTHER THEORY.

This warranty extends to each person who acquireslawful ownership within one year of the original retail

purchase for the High Frequency Arc Stabilizer but isvoid if it has been abused, altered, misused, orimproperly packaged and damaged when returned forrepair.

Some states do not permit the limitation of warrantiesor limitation of consequential or incidental damages, sothe above disclaimer and limitation may not apply toyou. This warranty gives you specific legal rights, andyou may also have other rights which vary from stateto state.

TO OBTAIN SERVICES UNDER THIS WARRANTY:

1. Owner pays transportation charges to the nearestservice center location.

2. Owner may avoid transportation charges, if hewishes, by calling WELDER SERVICE, at one ofthe telephone numbers listed below, for freediagnosis and immediate shipment of replacementparts. The owner, in this case, assumes theresponsibility for installation of parts.

For Service Center Locations call:Welder ServiceIn Minneapolis: (952) 884-3211Toll Free: (800) 328-2921

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