Miller Srh 503

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Processes

Description

Stick (SMAW) Welding

OM-2236 205 982GMay 2004

Air Carbon Arc (CAC-A) Cut-ting and Gouging

Arc Welding Power Source

Submerged (SAW) Welding

SRH-503

Visit our website at

www.MillerWelds.com

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Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you dont have time to do

it any other way.

Thats why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldnt afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. Theyre just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 7/03

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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Autres symboles relatifs l installation, au fonctionnement et lentretien de lappareil. 7. . . . . . . . . . .2-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. General Precautionary Label 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Input Connection Label 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Nameplate Safety Symbols 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. Do Not Lift 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Duty Cycle And Overheating 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Volt-Ampere Curves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Selecting A Location 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Dimensions And Weights 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Tipping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Selecting And Preparing Weld Output Cables 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8. Weld Cable Sizes 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Connecting To Weld Output Terminals 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Electrical Service Guide 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Placing Jumper Links 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Connecting Input Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Electrode/Amperage Selector 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE & TROUBLESHOOTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Fuse F1 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Troubleshooting Table 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 PARTS LIST 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND ACCESSORIESWARRANTY

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Notes

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OM-2236 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _8/03

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Y Marks a special safety message.

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.

D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present onunit.

D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

D Always verify the supply ground check and be sure that input

power cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

D When making input connections, attach proper grounding conduc-tor first double-check connections.

D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directlywith a separate cable.

D Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

D Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters.D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and themanufacturers instructions for metals, consumables, coatings,cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.

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OM-2236 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under yourhelmet.

D Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding caneasily 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 cancause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun ortorch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.D Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

D Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is inuse or connected for use.

D Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in Safety

Standards.

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OM-2236 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or nearcombustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift andsupport unit.

D If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle beforestarting to weld again.D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handlingboards or parts.

D Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.D Keep away from pinch points such as driverolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to doso.

D Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunicat ions equipment.

D Have only qualified persons familiar withelectronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

D If notified by the FCC about interference, stop using theequipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.D To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-tronic equipment.

D Be sure this welding machine is installed and groundedaccording to this manual.

D If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)

Y Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

For Gasoline Engines:Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductiveharm.

For Diesel Engines:Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andother reproductive harm.

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OM-2236 Page 4

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA022699101 (phone: 6177703000, website: www.nfpa.org and www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:8004636727or in Toronto 4167474044, website: www.csain-ternational.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 100368002 (phone: 2126424900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:6177703000,website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Officesphone for Region 5, Chicago, is3123532220,website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.

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OM-2236 Page 5

SECTION 2 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

som_fre 8/03

2-1. Signification des symboles

Signifie Mise en garde. Faire preuve de vigilance. Cette procdure prsente des risques identifis par lessymboles adjacents aux directives.

Y Identifie un message de scurit particulier.

. Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde. Faire preuve de vigi-lance. Il y a des dangers lis aux CHOCS LECTRIQUES, auxPICES EN MOUVEMENT et aux PICES CHAUDES. Se reporteraux symboles et aux directives ci-dessous afin de connatre les me-sures prendre pour viter tout danger.

2-2. Dangers relatifs au soudage larc

Y Les symboles ci-aprs sont utiliss tout au long du prsentmanuel pour attirer lattention sur les dangers potentiels et lesidentifier. Lorsquon voit un symbole, faire preuve de vigilance etsuivre les directives mentionnes afin dviter tout danger. Lesconsignes de scurit nonces ci-aprs ne font que rsumer lecontenu des normes de scurit mentionnes la section 2-4.Lire et respecter toutes ces normes.

Y Linstallation, lutilisation, lentretien et les rparations ne doi-vent tre confis qu des personnes qualifies.

Y Pendant lutilisation de lappareil, tenir lcart toute personne,en particulier les enfants.

LES DCHARGES LECTRIQUESpeuvent tre mortelles.Un simple contact avec des pices sous tension peutcauser une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tensionds que lappareil est en fonctionnement. Le circuit

dentre et les circuits internes de lappareil sont galement sous tension.En soudage semiautomatique ou automatique, le fil, le dvidoir, lelogement des galets dentranement et les pices mtalliques en contactavec le fil de soudage sont sous tension. Tout matriel mal install ou malmis la terre prsente un danger.

D Ne jamais toucher aux pices lectriques sous tension.

D Porter des gants et des vtements de protection secs et exempts detrous.D Sisoler de la pice et de la terre au moyen de tapis ou autres disposi-

tifs isolants suffisamment grands pour empcher tout contactphysique avec la pice ou la terre.

D Ne pas se servir dune source de courant alternatif dans les zones humi-des, les endroits confins ou l o on risque de tomber.

D Ne se servir dune source de courant alternatif QUE si le procd de souda-ge lexige.

D Si lutilisation dune source de courant alternatif savre ncessaire, se ser-vir de la fonction de tlcommande si lappareil en est quip.

D Couper lalimentation ou arrter le moteur avant de procder linstal-lation, la rparation ou lentretien de lappareil. Couper/tiqueterlalimentation selon la norme OSHA 29 CFR 1910.147 (voir les nor-mes de scurit).

D Installer et mettre la terre correctement lappareil conformment son manuel dutilisation et aux codes nationaux, provinciaux etmunicipaux.

D Toujours vrifier la terre du cordon dalimentation Vrifier et sassu-rer que le fil de terre du cordon dalimentation est bien raccord laborne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre.

D Pour excuter les branchements dentre, fixer dabord le conducteurde mise la terre adquat et contrevrifier les connexions.

D Vrifier frquemment le cordon dalimentation et sassurer quil nestni endommag ni dnud ; le remplacer immdiatement sil est en-dommag tout cble dnud peut causer une lectrocution.

D Mettre lappareil hors tension quand on ne lutilise pas.D Ne pas utiliser de cbles uss, endommags, de calibre insuffisant ou

mal pisss.D Ne pas senrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct.D Ne pas toucher llectrode quand on est en contact avec la pice, la

terre ou une lectrode dune autre machine.

D Nutiliser que du matriel en bon tat. Rparer ou remplacer surlechamp les pices endommages. Entretenir lappareil conformmentau prsent manuel.

D Porter un harnais de scurit quand on travaille en hauteur.

D Maintenir solidement en place tous les panneaux et capots.

D Fixer le cble de retour de faon obtenir un bon contact mtal surmtal avec la pice souder ou la table de travail, le plus prs possiblede la soudure.

D Ne pas connecter plus dune lectrode ou plus dun cble de masse unmme terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANTdans les convertisseurs aprs la suppression delalimentation lectrique.D Arrter les convertisseurs, dbrancher le courant lectrique et d-

charger les condensateurs dalimentation selon les instructionsnonces la section Entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz dontlinhalation peut tre dangereuse pour la sant.

LES FUMES ET LES GAZ peuventtre dangereux.

D Se tenir distance des fumes et ne pas les inhaler.

D lintrieur, ventiler la zone et/ou utiliser un dispositif daspiration auniveau de larc pour lvacuation des fumes et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur adductiondair agr.

D Lire les fiches techniques de santscurit (FTSS) et les instruc-tions du fabricant concernant les mtaux, les consommables, lesrevtements, les nettoyants et les dgraisseurs.

D Ne travailler dans un espace clos que sil est bien ventil ou porter unrespirateur adduction dair. Demander toujours un surveillant d-ment form de se tenir proximit. Des fumes et des gaz de soudagepeuvent se substituer lair, abaisser la teneur en oxygne et causerdes lsions ou des accidents mortels. Sassurer que lair est respira-ble.

D Ne pas souder proximit doprations de dgraissage, de nettoyageou de pulvrisation. La chaleur et les rayons de larc peuvent ragir enprsence de vapeurs et former des gaz hautement toxiques et irri-tants.

D Ne pas souder de mtaux munis dun revtement, tels que la tledacier galvanise, plombe ou cadmie, moins que le revtementnait t enlev dans la zone de soudage, que lendroit soit bien venti-l, et si ncessaire, porter un respirateur adduction dair. Lesrevtements et tous les mtaux renfermant ces lments peuvent d-gager des fumes toxiques lorsquon les soude.

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Le rayonnement de larc gnre des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des brlures oculaires et cutanes.Des tincelles sont projetes pendant le soudage.

LES RAYONS DE LARC peuvent cau-ser des brlures oculaires et cuta-nes.

D Porter un masque de soudage muni dun filtre de la nuance adquatepour se protger le visage et les yeux pendant le soudage ou pour re-garder (voir les normes de scurit ANSI Z49.1 et Z87.1).

D Porter des lunettes de scurit crans latraux sous le masque.

D Utiliser des crans ou des barrires pour protger les tiers de lclatblouissant ou aveuglant de larc ; leur demander de ne pas regarderlarc.

D Porter des vtements de protection en matire durable et ignifuge(cuir ou laine) et des chaussures de scurit.

Le soudage effectu sur des rcipients ferms tels quedes rservoirs, des fts ou des conduites peut causerleur clatement. Des tincelles peuvent tre projetesde larc de soudure. La projection dtincelles, les

pices chaudes et les quipements chauds peuvent causer desincendies et des brlures. Le contact accidentel de llectrode avec toutobjet mtallique peut causer des tincelles, une explosion, un surchauf-fement ou un incendie. Avant de commencer le soudage, vrifier etsassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut causer un incen-die ou une explosion.

D Se protger et protger les tiers de la projection dtincelles et de m-

tal chaud.D Ne pas souder un endroit o des tincelles peuvent tomber sur dessubstances inflammables.

D Placer toutes les substances inflammables une distance de 10,7 mde larc de soudage. En cas dimpossibilit, les recouvrir soigneuse-ment avec des protections agres.

D Des tincelles et des matires en fusion peuvent facilement passermme par des fissures et des ouvertures de petites dimensions.

D Surveiller tout dclenchement dincendie et tenir un extincteur proxi-mit.

D Le soudage effectu sur un plafond, un plancher, une paroi ou unecloison peut dclencher un incendie de lautre ct.

D Ne pas souder des rcipients ferms tels que des rservoirs, des ftsou des conduites, moins quils naient t prpars conformment lAWS F4.1 (voir les normes de scurit).

D Brancher le cble sur la pice le plus prs possible de la zone de sou-dage pour viter que le courant ne circule sur une longue distance, pardes chemins inconnus, et ne cause des risques dlectrocution et din-

cendie.D Ne pas utiliser le poste de soudage pour dgeler des conduites ge-

les.D En cas de non utilisation, enlever la baguette dlectrode du porte

lectrode ou couper le fil au raz du tubecontact.D Porter des vtements de protection exempts dhuile tels que des

gants en cuir, une chemise en tissu pais, des pantalons sans revers,des chaussures montantes et un masque.

D Avant de souder, retirer tout produit combustible de ses poches, telquun briquet au butane ou des allumettes.

LES PARTICULES PROJETES peu-vent blesser les yeux.

D Le soudage, le burinage, le passage de la pice la brosse mtallique et le meulage provoquent

lmission dtincelles et de particules mtalli-ques. Pendant leur refroidissement, les soudures risquent de projeter dulaitier.D Porter des lunettes de scurit crans latraux agrs, mme sous le

masque de soudage.

LES ACCUMULATIONS DE GAZ peu-vent causer des blessures ou mmela mort.

D Couper lalimentation en gaz protecteur en cas denon utilisation.

D Veiller toujours bien ventiler les espaces confins ou porter un respira-teur adduction dair agr.

LES PICES CHAUDES peuvent cau-

ser des brlures graves.D Ne pas toucher les pices chaudes main nue.D Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuventperturber le fonctionnement des stimu-lateurs cardiaques.

D Les personnes qui portent un stimulateur cardiaquedoivent se tenir distance.

D Ils doivent consulter leur mdecin avant de sappro-cher dun lieu o on excute des oprations de sou-dage larc, de gougeage ou de soudage par points.

LE BRUIT peut affecter loue.

Le bruit de certains processus et quipements peutaffecter loue.

D Porter des protecteurs doreille agrs si le niveausonore est trop lev.

Les bouteilles de gaz protecteur contiennent du gazsous haute pression. Toute bouteille endommagepeut exploser. Comme les bouteilles de gaz fontnormalement partie du procd de soudage, les

manipuler avec prcaution.

Les BOUTEILLES endommagespeuvent exploser.

D Protger les bouteilles de gaz comprim de la chaleur excessive, deschocs mcaniques, du laitier, des flammes nues, des tincelles et desarcs.

D Placer les bouteilles debout en les fixant dans un support stationnaireou dans un portebouteilles pour les empcher de tomber ou de serenverser.

D Tenir les bouteilles loignes des circuits de soudage ou autres cir-cuits lectriques.

D Ne jamais poser une torche de soudage sur une bouteille de gaz.D Ne jamais mettre une lectrode de soudage en contact avec une bou-

teille de gaz.D Ne jamais souder une bouteille contenant du gaz sous pression elle

risquerait dexploser.D Nutiliser que les bouteilles de gaz protecteur, rgulateurs, tuyaux et

raccords adquats pour lapplication envisage ; les maintenir en bontat, ainsi que les pices connexes.

D Dtourner la tte lorsquon ouvre la soupape dune bouteille.

D Laisser le capuchon protecteur sur la soupape, sauf en cas dutilisa-tion ou de branchement de la bouteille

D Lire et suivre les instructions concernant les bouteilles de gaz compri-m, les quipements associs et les publications P1 de la CGA,mentionnes dans les normes de scurit.

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2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien delappareil.

Risque DINCENDIE OU DEXPLO-SION

D Ne pas placer lappareil sur une surface inflam-mable, ni audessus ou proximit delle.

D Ne pas installer lappareil proximit de produits inflammables.

D Ne pas surcharger linstallation lectrique sassurer que lalimen-tation est correctement dimensionne et protge avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

D Nutiliser que lanneau de levage pour lever lap-pareil. NE PAS utiliser le chariot, les bouteilles degaz ou tout autre accessoire.

D Utiliser un engin de capacit adquate pour leverlappareil.

D Si on utilise un chariot lvateur pour dplacer lunit, sassurer queles fourches sont suffisamment longues pour dpasser du ct op-pos de lappareil.

LEMPLOI EXCESSIF peut FAIRESURCHAUFFER LQUIPEMENT.

D Prvoir une priode de refroidissement ; respec-ter le cycle opratoire nominal.

D Rduire le courant ou le cycle opratoire avant dereprendre le soudage.

D Ne pas obstruer les orifices ou filtrer lalimentation en air du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

D Mettre un bracelet antistatique AVANT de mani-puler des cartes ou des pices.

D Utiliser des pochettes et des botes antistatiquespour stocker, dplacer ou expdier des cartes decircuits imprims.

LES PICES MOBILES peuvent cau-ser des blessures.

D Se tenir lcart des pices mobiles.D Se tenir lcart des points de coincement tels

que les dvidoirs.

LES FILS DE SOUDAGE peuvent cau-ser des blessures.

D Ne pas appuyer sur la gchette avant den avoirreu linstruction.

D Ne pas diriger le pistolet vers soi, vers dautrespersonnes ou vers toute pice mcanique en en-gageant le fil de soudage.

LES ORGANES MOBILES peuventcauser des blessures.

D Se tenir lcart des organes mobiles comme lesventilateurs.

D Maintenir ferms et bien fixs les portes,panneaux, recouvrements et dispositifs de

protection.

LE RAYONNEMENT HAUTE FR-QUENCE (H. F.) risque de causer desinterfrences.

D Le rayonnement haute frquence peut causerdes interfrences avec les quipements de radio-navigation et de communication, les services descurit et les ordinateurs.

D Ne demander qu des personnes qualifies familiarises avec lesquipements lectroniques de faire fonctionner l installation.

D Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences causes par linstallation.

D Si la Federal Communications Commission signale des interfren-ces, arrter immdiatement lappareil.

D Faire rgulirement contrler et entretenir linstallation.D Maintenir soigneusement ferms les panneaux et les portes des sour-ces de haute frquence, maintenir le jeu dclatement au rglageadquat et utiliser une terre et un blindage pour rduire les interfren-ces ventuelles.

LE SOUDAGE LARC peut causerdes interfrences.

D Lnergie lectromagntique peut causer desinterfrences avec lquipement lectroniquesensible tel que les ordinateurs et lquipementcommand par ordinateur tel que les robots.

D Veiller ce que tout lquipement de la zone de soudage soit compati-ble au point de vue lectromagntique.

D Pour rduire la possibilit dinterfrence, maintenir les cbles de sou-

dage aussi courts que possible, les grouper, et les poser aussi basque possible (par ex. : terre).D Veiller souder une distance de 100 mtres de tout quipement

lectronique sensible.D Veiller ce que le poste de soudage soit pos et mis la terre confor-

mment au prsent manuel.D En cas dinterfrences aprs excution des directives prcdentes, il

incombe lutilisateur de prendre des mesures supplmentaires tel-les que le dplacement du poste, lutilisation de cbles blinds,luti lisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez dis-tance.

D Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.

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2-4. Principales normes de scurit

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(tlphone : (305) 4439353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers and Piping, norme American Welding Society AWSF4.1, de lAmerican Welding Society, 550 N.W. LeJeune Rd, Miami, FL33126 (tlphone : (305) 4439353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire ProtectionAssociation, P.O. Box 9101, 1 Battery March Park, Quincy, MA022699101 (tlphone : (617) 7703000, sites Web : www.nfpa.org etwww.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P1,de la Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (tlphone : (703) 4120900,site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca-nadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (tlphone : (800)4636727 ou Toronto : (416) 7474044, site Web : www.csainterna-tional.org).

Practice For Occupational And Educational Eye And Face Protection,norme ANSI Z87.1, de lAmerican National Standards Institute, 11 West42nd Street, New York, NY 100368002 (tlphone : (212) 6424900,site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, norme NFPA 51B, de la National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (tl-phone : (617) 7703000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, de lU.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a10 bureaux rgionaux Tlphone pour la Rgion 5, Chicago : (312)3532220, site Web : www.osha.gov).

2-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et les effets des champs magnti-ques basse frquence sur lorganisme

En parcourant les cbles de soudage, le courant cre des champs lec-tromagntiques. Les effets potentiels de tels champs restentproccupants. Cependant, aprs avoir examin plus de 500 tudes quiont t faites pendant une priode de recherche de 17 ans, un comitde spcialistes du National Research Council a conclu : Laccumula-tion de preuves na pas dmontr que lexposition aux champsmagntiques et aux champs lectriques haute frquence constitue unrisque pour la sant humaine . Toutefois, les tudes et lexamen despreuves se poursuivent. En attendant les conclusions finales de la re-cherche, il serait souhaitable de rduire lexposition aux champslectromagntiquespendant le soudage ou le coupage.

Afin de rduire les champs lectromagntiques en milieu de travail, res-pecter les consignes suivantes :

1. Garder les cbles ensemble en les torsadant ou en les fixant avec duruban adhsif.

2. Mettre tous les cbles du ct oppos loprateur.

3. Ne pas senrouler les cbles autour du corps.

4. Garder le poste de soudage et les cbles le plus loin possible de soi.

5. Placer la pince de masse le plus prs possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur mdecin. Si ce dernier les dclare aptes, il leur est recom-mand de respecter les consignes ci-dessus.

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SECTION 3 DEFINITIONS

3-1. General Precautionary LabelWarning! Watch Out! There arepossible hazards as shown by thesymbols.

1 Electric shock from weldingelectrode or wiring can kill.

1.1 Wear dry insulating gloves.Do not touch electrode withbare hand. Do not wear wet ordamaged gloves.

1.2 Protect yourself from electricshock by insulating yourselffrom work and ground.

1.3 Disconnect input plug orpower before working onmachine.

2 Breathing welding fumes canbe hazardous to your health.

2.1 Keep your head out of thefumes.

2.2 Use forced ventilation or localexhaust to remove the fumes.

2.3 Use ventilating fan to removefumes.

3 Welding sparks can causeexplosion or fire.

3.1 Keep flammables away fromwelding. Do not weld nearflammables.

3.2 Welding sparks can causefires. Have a fire extinguishernearby, and have awatchperson ready to use it.

3.3 Do not weld on drums or anyclosed containers.

4 Arc rays can burn eyes andinjure skin.

4.1 Wear hat and safety glasses.Use ear protection and buttonshirt collar. Use weldinghelmet with correct shade offilter. Wear complete bodyprotection.

5 Become trained and read theinstructions before working onthe machine or welding.

6 Do not remove or paint over(cover) the label.

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3-2. Input Connection Label1 Warning! Watch Out! There

are possible hazards asshown by the symbols.

2 Electric shock from wiring cankill.

3 Disconnect input plug orpower before working onmachine.

4 Read the Owners Manualbefore working on this

machine.5 Consult rating label for input

power requirements, andcheck power available at the

job site they must match.6 Read Owners Manual and

inside labels for connectionpoints and procedures.

7 Move jumper links as shownon inside label to matchvoltage at job site.

8 Having a loop of extra length,connect grounding conductorfirst.

9 Connect line input conductors

as shown on inside label double-check all connections,jumper link positions, andinput voltage before applyingpower.

S-179 290

1

4

5

3

2

? V? A

? V

3

1/96 1 2 3 4

5 6 87 9

3-3. Nameplate Safety Symbols1 Warning! Watch Out! There


2 Electric shock from weldingelectrode or wiring can kill.

3 Sparks from arcing electrodecan cause explosion or fire

disconnect cable for processnot in use.4 Read Owners Manual for

connection procedures.5 Electric shock from wiring can

kill.6 Disconnect input power

before working on unit ormaking terminal stripconnections.

Nameplate D-179 389

1

2 3 45 6

1

3-4. Do Not Lift

2

206 403

1 3 4 1 Warning! Watch Out! There


2 Falling equipment can causeserious personal injury andequipment damage.

3 Do not use handles to liftsystem. Handles are notdesigned to support weight ofsystem.

4 Use lifting eye to lift unit only,Not running gear. Lift onlywith proper equipment andcorrect procedures. Usehandle only to move unit.

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SECTION 4 INSTALLATION

4-1. Specifications

Rated Weldin

Amperes Input at Rated LoadOutput, 60 Hz, Three-Phase

Model

Output Amp Range DC Max OCV DC 220-230 V 440-460 V KVA KW

500 Amp 500 A @ 40 Volts DC,60% Duty Cycle50 525 77 98

4.5*49

2.2*38.91.8*

260.7*

*While idling

4-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

Y Exceeding duty cycle candamage unit and voidwarranty.

Overheating0

15

V

ORReduce Duty CycleMinutes 205 909

60% Duty Cycle At 500 Amperes For 500 Ampere Models

6 Minutes Welding 4 Minutes Resting

10 20 30 40 50 60 70 80 90100100

200

300

400

500600700800900

1000

% DUTY CYCLE

WELDAMPERES

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4-3. Volt-Ampere Curves

Volt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofunit. Curves of other settings fall be-tween curves shown.

206 054

4-4. Selecting A Location1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Rating Label

Use rating label to determine inputpower needs. Label located underfront access door.

4 Line Disconnect Device

Locate unit near correct inputpower supply.

Y Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

34

18 in(460 mm)

18 in(460 mm)

OR

1

2

Movement

Location And Airflow

Ref. 803 025-D

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4-5. Dimensions And Weights

C

mens ons w unn ng ear n ye

DE Height 35-1/4 in (895 mm)

4 Holes Width 28 in (711 mm)

Depth 33-1/2 in (851 mm)

A 27-1/2 in (699 mm)

B 3/4 in (19 mm)

C 21-1/8 in (537 mm)

D 1-1/8 in (29 mm)

E 7/16 in (11 mm) Dia

Weight

B 801 530410 lb (186 kg)

4-6. TippingY Be careful when placing or

moving unit over unevensurfaces.

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4-7. Selecting And Preparing Weld Output Cables

10 ft (3 m)

1

Total CableLength In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

2

4

3

2

Tools Needed:

sb6.1 11/92 S-0653

1 Weld Output Cable

Determine total cable length in weldcircuit and maximum welding am-peres. See Section 4-8 to selectproper cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperagecapacity and hole size for connect-ing to work clamp, electrode holder,and weld output terminals.

3 Insulated Electrode Holder

Install according to manufacturersinstructions.

4 Work Clamp

Install onto work cable.

4-8. Weld Cable SizesTotal Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

WeldingAmperes

10 To 60%Duty Cycle

60 Thru 100%Duty Cycle 10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

*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. Contact your distributor forthe mm2 equivalent weld cable sizes. S-0007-E

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4-9. Connecting To Weld Output Terminals

Ref. 803 026-C

Tools Needed:

1 2

3/4 in

Y Turn off power before con-necting to weld outputterminals.

1 Positive (+) Weld OutputTerminal

2 Negative () Weld OutputTerminal

3 Cable Restraint

Route weld cables through cablerestraint.

For DC Electrode Positive (DCEP),connect work cable to negative ()terminal,and connect electrodeholder cable to positive (+) terminal.

For DC Electrode Negative(DCEN), reverse cableconnections.

3

4-10. Electrical Service Guide

Input Voltage 220-230 440-460Input Amperes At Rated Output 98 49

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay 2 100 50

Normal Operating 3 150 70

Min Input Conductor Size In AWG/Kcmil 4 8

Max Recommended Input Conductor Length In Feet (Meters)148(45)

258(79)

Min Grounding Conductor Size In AWG/Kcmil 6 8

Reference: 1999 National Electrical Code (NEC)1 Consult factory for circuit breaker applications.

2 Time-Delay fuses are UL class RK5 .3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

above).

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OM-2236 Page 16

4-11. Placing Jumper Links

Y Disconnect and lockout/tag-out input power beforeinstalling or moving jumperlinks.

Check input voltage available atsite.

1 Jumper Link Label

Check label only one is on unit.

2 Jumper LinkMove jumper links to match inputvoltage, and label on unit.

Close access door, or go on to Sec-tion 4-12.

1

3/8, 1/2 inRef. ST-800 103-A

2

Do notovertighten

jumper link nuts.

208 380A

220230 VOL 440460 VOLTS TS

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OM-2236 Page 17

4-12. Connecting Input Power

800 103-C / Ref. 801 116-A

3/8 in

3/8 in

Tools Needed:

Y Installation must meet all Nationaland Local Codes have only quali-fied persons make this installation.

Y Disconnect and lockout/tagout in-put power before connecting inputconductors from unit.

Y Make input power connections tothe welding power source first.

Y Always connect green or green/

yellow conductor to supplygrounding terminal first, and neverto a line terminal.

See rating label on unit and check inputvoltage available at site.

1 Input Power Conductors (CustomerSupplied Cord)

Select size and length of conductors usingSection 4-10. Conductors must complywith national, state, and local electricalcodes. If applicable, use lugs of properamperage capacity and correct hole size.

Welding Power Source Input PowerConnections

2 Strain Relief

Route conductors (cord) through strain re-lief and tighten screws.

3 Machine Grounding Terminal

4 Green Or Green/Yellow GroundingConductor

Connect green or green/yellow groundingconductor to welding power sourcegrounding terminal first.

5 Welding Power Source LineTerminals

6 Input Conductors L1 (U), L2 (V) AndL3 (W)

Connect input conductors L1 (U), L2 (V)and L3 (W) to welding power source lineterminals.

Close and secure access door on weldingpower source.

Disconnect Device Input Power Con-nections

7 Disconnect Device (switch shown inOFF position)

8 Disconnect Device (Supply)Grounding Terminal

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

9 Disconnect Device Line Terminals

Connect input conductors L1 (U), L2 (V)And L3 (W) to disconnect device line

terminals.10 Over-Current Protection

Select type and size of over-currentprotection using Section 4-10 (fused dis-connect switch shown).

Close and secure door on l ine disconnectdevice. Remove lockout/tagout device,and place switch in the On position.

IMPORTANT

GND/

3

PE Earth Ground

Input Contactor

L1 (U)

L2 (V)

L3 (W)

= GND/PE Earth Ground

7

2

10

5

3

6

4

8

4

9

1

=

6

3

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OM-2236 Page 18

SECTION 5 OPERATION5-1. Controls

2

1

3

1 Power Switch W/IndicatorLamp

When the switch is turned on, thelamp lights to indicate power hasbeen applied to the unit.

Y If the indicator lamp does not

light when the power switchis turned on, replace theswitch.

NOTE:This unit has over-tempera-ture protection. If unit becomes hotor if the duty cycle is exceeded (seeSection 4-2), weld output shutsdown and the fan stops running.The indicator lamp on the powerswitch remains on.

Y When the unit has cooleddown, the fan restarts airflow, and weld output ispresent at the weld outputterminals and/or at the elec-trode.

2 Amperage Adjustment Control3 Amperage Range Indicator

Turn handle clockwise to increaseamperage as indicated by the am-perage range indicator.

803 026-C

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OM-2236 Page 19

5-2. Electrode/Amperage Selector

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OM-2236 Page 20

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replaceunreadablelabels.

Clean andtighten weldterminals.

Repair orreplacecrackedweldcable.

6 Months

Blow out or vacuum inside.During heavy service, cleanmonthly

Or

6-2. Fuse F1

Ref. ST-800 101-C

Y Disconnect and lockout/tag-out input power before open-ing rear access door tochange fuse.

1 Fuse Holder Cover2 Fuse F1 (See Parts List For

Rating)

Fuse F1 protects control transform-er from overload. If F1 opens, weldoutput and fan motor stops. Re-place F1.

Close rear access door.

Tools Needed:

3/8 in

21

Turn Pull Out And Replace Fuse(Install Flat End Of Fuse Into Cover)

Turn

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OM-2236 Page 21

6-3. Troubleshooting Table

Trouble Remedy

No weld output; unit completelyinoperative.

Place line disconnect switch in On position (see Section 4-12).

Check fuse F1 and replace if necessary (see Section 6-2).

Check and replace line fuse(s) if necessary (see Section 4-12).

Check for proper input power connections (see Section 4-12).

Check for proper jumper link position (see Section 4-11).

No weld output, power switch light on,but fan off.

Unit overheated, allow unit to cool (see Section 4-2). NOTE: When unit has cooled, fan starts andweld output is present at the weld output terminals and/or at the electrode.

No weld output, but fan on. Clean and tighten all weld connections (see Section 6-1).

Unit provides only low or minimum

Check for proper line voltage (see Section 4-12).we ou pu .

Check for proper input power connections (see Section 4-12).


Check for open line fuse(s), and replace if necessary (see Section 4-12).

Clean and tighten all weld connections (see Section 6-1).

Select correct size weld cables (see Sections 4-7 and 4-8).

Have factory authorized Service Agent check rectifier SR1.

Erratic or improper weld output. Check for proper input power connections (see Section 4-12).

Use proper size and type weld cables (see Sections 4-7 and 4-8).

Clean and tighten all weld connections (see Section 6-1).

Use proper size and type electrodes.

Have factory authorized Service Agent check rectifier SR1.

Excessive line current or line fuse(s)

Check for proper input power connections (see Section 4-12).open repeatedly.


Fan not operating and/or over heating. Check for and remove anything blocking fan movement.

Have factory authorized Service Agent check fan motor.

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OM-2236 Page 22

Notes

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OM-2236 Page 23

SECTION 7 ELECTRICAL DIAGRAM

205 900-C

Figure 7-1. Circuit Diagram

. For Primary Circuit Diagram Portion, refer to Circuit Diagramlocated inside wrapper of welding power source.

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OM-2236 Page 24

SECTION 8 PARTS LIST

ST-803 137-D

. Hardware is common andnot available unless listed.

1

2

8

10

9

5

27

1

11

12

1

3

14

15

17

16

18

6

7

34

19

4

2

3

28

29

30

33

32

31

38

39

47

36

40

35

48

44

42

41

43

45

37

34

50

58

57

56

49

51

5253

54

55

49

25

24

23

22

212

0

26

59

60

61

62

60

Figure 8-1. Main Assembly

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OM-2236 Page 25

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Main Assembly

Quantity

1 176254 LABEL,GENERAL PRECAUTIONARY WORDLESS,INTL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 +179430 PANEL,SIDE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 205910 BAFFLE,AIR LOWER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 205911 BAFFLE,AIR UPPER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 +206585 COVER,TOP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 206403 LABEL,CAUTION DO NOT LIFT WORDLESS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 207866 LABEL,ROD TYPE&SIZE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 177279 GASKET,LIFT EYE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 162830 LIFT EYE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 162820 BAR,MTG LIFT EYE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 FM 208 402 MOTOR,1/12HP 230V 1550 RPM 50/60HZ .83A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 124274 BRACKET,MTG FAN MOTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 173283 CHAMBER,PLENUM 14 IN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 180165 BLADE,FAN 14.000 3WG 28DEG .375 BORE CCW GAL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 162807 PANEL,REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 168343 HINGE,CONT POLYOLEFIN COPOLYMER 2.000 L W/.125H 2. . . . . . . . . . . . . . . . . . . . . . . . . . .17 +162818 DOOR,ACCESS PRIMARY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 179290 LABEL,WARNING ELECTRIC SHOCK INPUT CONNECTION CE W 1. . . . . . . . . . . . . . . . . . . .19 010467 CONN,CLAMP CABLE 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 TE1 159244 PRIMARY BOX, (CONSISTING OF) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 601835 NUT 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 038887 STUD, PRI BD BRS 10-32 X 1.375 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038618 LINK, JUMPER TERM BD PRI 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601835 NUT, 10-32 BRS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010913 WASHER, FLAT .218 ID BRS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 159034 HOLDER, FUSE MINTR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 F1 *156065 FUSE, CRTG .5A 600V TIME DELAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 W 160793 CONTACTOR, DEF PRP 60A 3P 24VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 T2 208382 XFMR, CONTROL 50VA 24V 220/440 (60HZ) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 162816 CHANNEL,UPRIGHT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 209869 WHEEL,POLYOLEFIN 10 IN DIAX 2.00WIDEX.750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 121614 RING,RTNG EXT .750 SHAFT X .085 THK E STYLE PLD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 205998 AXLE,RUNNING GEAR .750 DIA X 27.703 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 008999 CASTER,SWVL 4.00 IN POLYOLEFIN 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 163442 SUPPORT,CASTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 163533 BASE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 207663 RECITIFER,SI DIODE 500 AMP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 181245 TERMINAL,PWR OUTPUT RED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 181246 TERMINAL,PWR OUTPUT BLACK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 205976 NAMEPLATE,MILLER SRH503 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 S1 159039 SWITCH,ROCKER SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 205914 PANEL,FRONT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 205948 NAMEPLATE,MILLER SRH503 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 190296 GEAR,INDICATOR PINION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 190295 GEAR,INDICATOR POINTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 190241 HANDLE,CONTROL CURRENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 010828 HANDLE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 186621 BOOT,GENERIC OUTPUT STUD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 180735 WASHER,OUTPUT STUD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 181169 SPACER,OUTPUT STUD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 195130 KIT, LEAD SCREW REPLACEMENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 205985 ASSEMBLY,LAMINATION 45 DEG MOVABLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 205912 BRACKET,MTG LAMINATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 205986 ASSEMBLY,LAMINATION 45 DEG STATIONARY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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OM-2236 Page 26

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

8-1. Main Assembly (continued)

Quantity

53 205885 SPACER,STL .500 ID X .625 OD X 1.267 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 024620 SPROCKET,W/1/8 HOLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 206010 CHAIN,ROLLER NO 43 1/4X54 PITCHES LG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 010660 PIN,SPRING CS .125 X 1.125 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 204960 SPRING,CPRSN .625 OD X .123 WIRE X 1.500 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 T1 204956 XFMR,POWER MAIN 220/440 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP1, 2, 3 208381 THERMOSTAT,NC OPEN 135C CLOSE 135C W/INSUL LEADS. . . . . . . . . . . .(included w/T1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 604536 SCREW, 312-18 X 1.75 HEX HD-PLN GR5 PLD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 217136 LABEL, WARNING ELECTRIC SHOCK 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 217864 LABEL, CAUTION DO NOT LIFT (FR) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 217138 LABEL, WARNING ELECTRIC SHOCK/INPUT POWER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

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Warranty Questions?

Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 3/04

Your distributor also givesyou ...

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

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

guarantees or warranties expressed or implied.

LIMITED WARRANTY Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants toits original retail purchaser that new Miller equipment sold afterthe effective date of this limited warranty is free of defects inmaterial and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair orreplace any warranted parts or components that fail due to suchdefects in material or workmanship. Miller must be notified inwriting within thirty (30) days of such defect or failure, at whichtime Miller will provide instructions on the warranty claimprocedures to be followed.

Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date that theequipment was delivered to the original retail purchaser, or one

year after the equipment is sent to a North American distributoror eighteen months after the equipment is sent to anInternational distributor.

1. 5 Years Parts 3 Years Labor

* Original main power rectifiers* Inverters (input and output rectifiers only)

2. 3 Years Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders* Inverter Power Supplies (Unless Otherwise Stated)

* Intelli tig* Maxstar 150

* Engine Driven Welding Generators(NOTE: Engines are warranted separately by

the engine manufacturer.)3. 1 Year Parts and Labor Unless Specified

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of SpoolmateSpoolguns)

* Process Controllers

* Positioners and Controllers* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources* Water Coolant Systems

* Flowgauge and Flowmeter Regulators (No Labor)* HF Units

* Grids

* Maxstar 85, 140* Spot Welders

* Load Banks* Arc Stud Power Sources & Arc Stud Guns

* Racks* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAFModels)

* Field Options(NOTE: Field options are covered under TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year whichever is greater.)

4. 6 Months Batteries

5. 90 Days Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets* APT & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

Millers True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, slip rings,relays or parts that fail due to normal wear. (Exception:brushes, slip rings, and relays are covered on Bobcat,Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others,such as engines or trade accessories. These items are

covered by the manufacturers warranty, if any.3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,improperly operated or misused based upon industrystandards, or equipment which has not had reasonableand necessary maintenance, or equipment which hasbeen used for operation outside of the specifications for theequipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE ANDUSE BY COMMERCIAL/INDUSTRIAL USERS ANDPERSONS TRAINED AND EXPERIENCED IN THE USE ANDMAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Millers option: (1) repair; or (2)replacement; or, where authorized in writing by Miller inappropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Miller service station; or (4)payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods atcustomers risk and expense. Millers option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Miller authorized service facility as determined byMiller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT ORANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN ANDANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATIONOF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENTFURNISHED BY MILLER IS EXCLUDED AND DISCLAIMEDBY MILLER.

Some states in the U.S.A. do not allow limitations of how long animplied warranty lasts, or the exclusion of incidental, indirect,special or consequential damages, so the above limitation orexclusion may not apply to you. This warranty provides specificlegal rights, and other rights may be available, but may varyfrom state to state.

In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein,and to the extent that they may not be waived, the limitationsand exclusions set out above may not apply. This LimitedWarranty provides specific legal rights, and other rights may beavailable, but may vary from province to province.

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Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International HeadquartersUSAUSA Phone: 920-735-4505 Auto-AttenUSA & Canada FAX: 920-735-4134

International FAX: 920-735-4125European Headquarters United KingdomPhone: 44 (0) 1204-593493FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Call 1-800-4-A-Miller or see our website at www.MillerWelds.comto locate a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Informationand Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owners Record

File a claim for loss or damage duringshipment.

For assistance in filing or settling claims, contact

Contact your Distributor for: