EX300 (230/460 and 460/575 Volt Models) - Red-D
Contents
1. o 0 O 0 O O oT T 7 mca 3 un A C4 PC2 o RC1 PLG13 cn RC2 PLG14 RC3 PLG21 1 18 c1 1 8 s al m e Nasa c a ad V V V Y PEREA X qo des D O RCI PLGIS D O O RCI PLG16 t tc dX r e oe Y Y Y Y V Y Y Y x X A x SPX amp x Rp x amp S Sa sius a a eda A A_A_A_ K AA AA ATATA A A A AA AA AA a NR HO o vo ON SIE ht LE qe m o 3 4 ROLE gt DS RDA D N Q Q M o 00009 o D OG 9 5 U E EEES IE M D e RC3 4 gt Rc3 2 SD RC1 PLG1 eye vie HD1 Gi RC4 PLG4 RC6 2 gt gt RE rcs ZE a NEU CONTROL BOARD RC7 PLG7 u T RCB PLGB RC9 PLG19 c7 TP1 PLG20 Rc8 25 PL OR BLUE 42 4321 YA Y Ye pico Y Y Y Y 1 CCS OPTION geND ena 42 I I ZEN TT LI LAE Ae xx el I SR1 ASE RN A a O GAN ji RT o I ro AK BLA z 4 A LI I I I I I iz olod oam 2 I I I I igs AED RED A A I L Em Po cen eO ID PR OP PE P o Z W2A 4 w2 5 W2A 2 SRCS 1 4 INT E lt lt RC3 3 RC10 y PLG10A N 2 2 z K ars 8 GES GPTON O y N S 1030 Y Y I I QO ROT Logona N T2 i ek aki p 4 TETET I 1 mM HART Mee 2 a 184 I I I I 8S 8 qu I I I I VV vv I I 1 107 8 9 I I YY Y Y I I I I m 9 Lid cbe ni2. 2 56s L2 C7 8 186 543 sa CAPAGITOR 4 exeun eade Ere tens sda eA E Pee Us dst eor ie d 2 KDE VAR rre 185 732 ee PANEEL MOOL iia erae re ADR tier aO e A aa 1 LOO E ae tes 129 525 RECEPTACLE twlk insul fem 2 IO espe ben nete pus un NAMEPLATE order by model and serial number 1 he BO e iR et 174992 KNOB pointer 840 2 20014 kisses 175 855 14 DOOR TOM 7222s iu hien ke ed be bes SE A 1 B2 ouch 174991 KNOB pointer 1 250 2 O3 Session 176 226 INSULATOR switch power 1 64 S1 128 756 SWITCH tgl 3PST 40A 600VAC 1 Os 134 327 LABEL warning general precautionary 2 When ordering a component hginally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2208 Page 28 Notes OM 2208 Page 29 Notes OM 2208 Pag
3. OM 2208 Page 11 3 2 Weld Output Receptacles And Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 150 ft 200ft 250ft 300ft 350ft 400ft 100ft 30m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Turn off power before 10 6096 60 100 connectingto weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x70 2 ea 2 0 2ea
4. 6 Months MN d Blow Out Inside Z OM 2208 Page 20 5 2 Voltmeter Ammeter Help Displays HE L HE L U I SHE L P 2 i HE L P 3 5 i 10 HE L gt All directions are in reference to the front of the unit All circuitry referred to is lo cated inside the unit 1 Help 0 Display Indicates a shorted thermistor RT2 on the left side of the unit If this display is shown con tact a Factory Authorized Service Agent 2 Help 1 Display Indicates a malfunction in the primary power circuit If this display is shown contact a Fac tory Authorized Service Agent 3 Help 2 Display Indicates a malfunction in the thermal protection circuitry located on the left side of the unit If this display is shown contact a Factory Authorized Service Agent 4 Help 3 Display Indicates the left side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 2 2 Operation will continue when the unit has cooled 5 Help 4 Display Indicates a malfunction in the thermal protection circuitry located on the right side of the unit If this display is shown contact a Factory Authorized Service Agent 6 Help 5 Display Indicates the right side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 2 2 Operation will continue when the unit has cooled 7 Help 6 Display Indicates that the input
5. OM 2208 175 493N January 2001 Processes Multiprocess Welding Y 9 4 ANN VOW escription RED D ARC E ER 3 Es Welderentals www red d arc com EX300 230 460 and 460 575 Volt Models CC CV and CC Models OWNERS MANUAL 4 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq The following terms are used interchangeably throughout this manual TIG GTAW Stick SMAW OM 2208 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 4 1 Symbol Usage isset Eh exakt ses se TA AERA takai ess 1 1 2 Arc Welding Hazards 22 1 1 3 Additional Symbols for Installation Operation and Maintenance 3 1 4 Principal Safety Standards 3 1 55 EMF Information i A eat A Lue ien 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 1 Sighification des symboles veresen re vo ee ex Rer RESET ee es ERE DRE ERE de 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et l Maintenance
6. Minutes Reduce Duty Cycle gt sduty1 5 95 SA 178 651 OM 2208 Page 9 2 3 Volt Ampere Curves VOLTS VOLTS 100 80 60 40 20 100 80 60 40 20 A CC Mode SMAW MAX LT A CONTROL D 100 200 300 400 500 AMPERAGE B CV Mode MAX MN O 100 200 300 400 500 AMPERAGE Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown va curve1 4 95 SA 178 652 SA 178 653 OM 2208 Page 10 SECTION 3 INSTALLATION 3 1 Selecting a Location e ve RT WMA MES Dimensions And Weight 76 Ib 34 6 kg 17 in 432 mm Ve m 12 1 2 in 318 mm Movement 1 Lifting Handles Use handles to lift unit 2 Hand Cart Do not move or operate unit soy where it could tip Use cart or similar device to move unit 3 Rating Label Use rating label to determine input power needs 4 Line Disconnect Device Locate unit near correct input D power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 LJ Location INPUT SERIAL NO STOCK NO VOLTS AMPERES KW PHASE HERTZ loc_2 3 96 Ref ST 151 556 ST 801 192
7. 1 43 Zl ss 173 370 S TABIEIZER a tette en S Rt etr enr Line 1 44 Lise 173563 INDUCTOR input 444 442 1 D POTERIT 173631 HEAT SINK power module 1 46 Ti 173811 TRANSFORMER HF 230 460 1 AB Moa 180952 TRANSFORMER HF 460 575 1 b AERE ona nas ef 175 192 HENAT SINK T l ette nn Ren Ree Ret tecti aut 1 48 175255 INSULATOR rectifier 1 A eal IT 110 386 RELAY 24VAC 460 575 only 1 BAS AR Aa 173693 FOOT mtg unit 4 gue DO sss d teed ced eum T 176 736 SCREW mlg IOO 22 tek esha ods SERRE ah ie D HR REESE Y Re LER 4 PST reda nd mess 175132 BASE aed ays Baie Paes ne AA mm ne E NMR 1 OQ ues PC3 190 704 CIRCUIT CARD front panel display CC model 1 EP see PC3 190 700 CIRCUIT CARD front panel display CC CV model 1 RSR PLG11 115091 CONNECTOR amp SOCKETS RC2 1 SEE FM 175084 MOTOR fan 24VDC 3000RPM 1 54 RC1 185 730 RECEPTACLE w leads amp plug 1 Riot ee ar nate etes 178548 TERMINAL connector friction
8. A Always connect grounding conductor first L 3 GND PE a Tools Needed IZ 3 8 in CARA 3 8 in input 9 99 Ref ST 144 221 Ref ST 070 399 C ST 801 192 OM 2208 Page 15 SECTION 4 OPERATION 4 1 Front Panel Controls For CC CV Model 1 Power Switch IP The fan motor is thermostatically controlled and only runs when cooling is needed 2 Voltmeter see Section 4 3 3 Ammeter see Section 4 3 4 V A Voltage Amperage Adjustment Control 5 Mode Switch The Mode switch setting determines both the process and output On Off control see Sec tion 4 4 Source of control panel or remote for the amount of output is selected on the V A Control switch For Air Carbon Arc CAC A cutting and gouging place switch in Stick position For best results place Inductance Dig control in the maximum position 6 V A Voltage Amperage Control Switch For front panel control place switch in Panel position and use the V A Adjust control For remote control make connections to Re mote 14 receptacle and place switch in Re mote position In most modes remote con trol is a percent of V A Adjust control setting value selected on V A Adjust is maximum available on remote In the MIG mode re mote control provides full range of unit output regardless of V A Adjust control setting 7 Inductance Dig Control Control adjusts Dig when St
9. 3 0 2ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 ea 2 0 2ea 3 0 2ea 3 0 2ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2x120 2ea 2 0 2ea 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 2x120 Output Receptacles 2 ea 2 0 2ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 5 70 2x95 2x120 3x95 3x95 2ea 2 0 2ea 3 0 2ea 4 0 3ea 3 0 3ea 4 0 3 ea 4 0 600 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 cable mm for metric use For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 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 This chart is a general guideline and may not suit all applications If cable overheating occurs normally you can smell it use next size larger S 0007 E OM 2208 Page 12 3 3 Remote 14 Receptacle Information lA REMOTE 14 Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit breaker CB2 OUTPUT B Contact closure to A completes 24 volts ac CONTACTOR contactor control circuit 115 VOLTS AC I 115 volts ac Protected by circuit breaker CB1 OUTPUT J Contact closure to com
10. one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue amp 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 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacem
11. while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 2208 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Weara welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible t
12. 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA O 2001 Miller Electric Mfg Co 1 01
13. Do not point gun toward any part of the body other people or any metal when threading welding wire 5 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained
14. Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from Na
15. display the actual weld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle Meter Reading While Welding V A V A a 80 0 85 10 3 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Lift Arc TIG 7 0 85 10 3 85 Actual Volts Preset Amps Actual Volts Actual Amps V A V A TIG 85 10 3 85 Blank Preset Amps Actual Volts Actual Amps V A V A MIG 24 5 24 5 250 Preset Volts Blank Actual Volts Actual Amps V A V A pes PPP PPP 24 5 250 Pulse Display Pulse Display Actual Volts Actual Amps V A V A cc 85 24 5 85 Blank Preset Amps Actual Volts Actual Amps V A V A Stick 80 0 85 24 5 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A pedes 80 0 24 5 250 Flashes OCV And Preset Blank Actual Volts Actual Amps 4 4 Mode Switch Settings For CC CV Model NOTE gt The Stick and CC modes provide the Adaptive Hot Start feature which automatically increases the output amperage at the start of a weld should the start require it This eliminates electrode sticking at arc start Mode Switch Setting Process Output On Off Control Scratch Start TIG GTAW Electrode Hot Lift Arc TIG GTAW See Section 4 7 Electrode Hot TIG GTAW With HF Unit Pulsing Device Or Remote Control At Remote 14 MIG GMAW At Remote 14 Pulsed MIG GMAW P Requires an external pulsing device At Remote 14 CC Stick SMAW With Remote On Off At Remote 14 Stick S
16. e sd red ree ur Eee iue re at PRENNE IT RA E e 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 INTRODUCTION seeeeeeeeee nnnm n nnn 9 2 1 Specifications edere eh eRRRCERUELATATPNERNUEENUDONRPN ENTE B A Eres 9 2 2 Duty Cycle And Overheating 9 2 3 Volt Ampere Curves 10 SECTION 3 INSTALLATION 44444 4444444 scene 11 3 1 Selecting a Location eoe eG GA RT Rr AE a EE E Gr aes 11 3 2 Weld Output Receptacles And Selecting Cable Sizes 12 3 3 Remote 14 Receptacle Information 13 3 4 Optional 115 Volts AC Duplex Receptacle And Circuit Breakers 13 3 5 Electrical Service Guide ereenn he tere sek ener c ees elei e over Se 14 3 6 Connecting Input Power 15 SECTION 4 OPERATION 44444 44444 sise 16 4 1 Front Panel Controls For CC CV Model 16 4 2 Front Panel Controls For CC Model 17 4 3 Meter Functions For CC CV Model 18 4 4 Mod
17. switch in one of the Stick positions For best results place Dig control in the maximum position 6 V A Voltage Amperage Control Switch For front panel control place switch in Panel position and use the V A Adjust control For remote control make connections to Re mote 14 receptacle and place switch in Re mote position Remote control is a percent of V A Adjust control setting Value selected on V A Adjust is maximum available on remote 7 Dig Control When set towards minimum short circuit amperage at low arc voltage is the same as normal welding amperage When set towards maximum short circuit amperage is increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding see volt ampere curves in Section 2 3 Select setting best suited for application When a TIG process is selected on the mode Switch this control is not functional C336 POWER LIFT ARC TIG STICK Foster SCRATCH START TIG V A ADJUST e Ref ST 175 500 OM 2208 Page 17 4 3 Meter Functions For CC CV Model NOTE The meters
18. voltage is too low and the unit has automatically shut down Opera tion will continue when the voltage is within the acceptable lower range limit 15 below the applicable input voltage If this display is HE L HE L HE L HE L HE L U U N dl shown have an electrician check the input voltage 8 Help 7 Display Indicates that the input voltage is too high and the unit has automatically shut down Operation will continue when the voltage is within the acceptable upper range limit 15 above the applicable input voltage If this display is shown have an electrician check the input voltage Help 7 can also indicate a bus voltage imbalance 9 Help 8 Display Indicates a malfunction in the secondary power circuit of the unit If this display is shown contact a Factory Authorized Ser vice Agent 10 Help 9 Display Indicates a shorted thermistor RT1 on the right side of the unit If this display is shown contact a Factory Authorized Service Agent OM 2208 Page 21 5 3 Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown ST 801 192 5 4 Troubleshooting pow J NN 2 Trouble Remedy No weld output unit completely inop erative Place line disconnect switch in On position see Section 3 6 Check and replace l
19. 25V pog p A 182445 NUT 1 000NPT sinc d riens CB1 089 807 CIRCUIT BREAKER man reset 1P 2 5A 250VAC 16 CB1 083 432 CIRCUIT BREAKER man reset 1P 10A 250VAC Cd ut CB2 083 432 CIRCUIT BREAKER man reset 1P 10A 250VAC Bi Sines marec 175447 PANEL Teal desee baa dota ar eee eos cadet ako err eee err crea eee 186 441 BUSHING strain relief 710 980 ID x 1 375 VON MU I HEP TEENS EE 186 469 CABLE power EET PLATE ident rear order by model and serial number 2 CR 175 282 COVER receptacle et 175 138 BOX lo vet seek anni nee a edo DO os ep ene ers 148 329 LABEL caution incorrect voltage 230 460 Dl A 182 227 LABEL caution incorrect voltage 460 575 OA HRi dure 192 853 BRACKET mtg contactor capacitor PC Board 295 PC1 193 752 CIRCUIT CARD control 230 460 25552 PC1 193 759 CIRCUIT CARD control 460 575 s PLG2 131056 CONNECTOR amp SOCKETS RC2 TENUES pedi PLG3 130203 CONNECTOR 8 SOCKETS RC3 ainda m PLG4 115094 CONNECTOR amp SOCKETS RC4 E P
20. 7 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un PS incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tinc
21. Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risgue D INCENDIE OU f D EXPLOS
22. ION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour Soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn Y i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT a e Pr voir une p riode de refroidissement respec v ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s y E e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobile
23. LG5 115091 CONNECTOR amp SOCKETS RC5 A ST AU GS De A d PLG7 115093 CONNECTOR amp SOCKETS RC7 RS RE e 26 RC10 166679 CONNECTOR 8 SOCKETS 27 W1 2 175082 CONTACTOR def prp 40A 24VAC coil 230 460 only RS OR artem ts 173 763 STAND OFF No 10 32 x 1 418 230 460 only A eus T2 201 684 TRANSFORMER control 230 460 ecd Lee T2 193774 TRANSFORMER control 230 460 URNA DNE T2 25i 180 963 TRANSFORMER control 460 575 EE o rican T2 180962 TRANSFORMER control 460 575 MERS c aed SME 183 549 BRACKET mtg aux transformer xd SES a iila 192855 WINDTUNNEL RH sssssseeesss e eee CLR eue 153403 BUSHING snap in nyl 750 ID x 1 000mtg A TR TE 177 547 BUSHING snap in nyl 1 125mtg 39 53 CT1 175199 TRANSFORMER current 94 nn mue 025248 STAND OFF insul 35s iu Cl zx 186 015 CAPACITOR polyp film 34uf 1000VAC 230 460 Sie G1 2 186 549 CAPACITOR polyp film 27uf 1000VAC 460 575 When ordering a component rginally displaying a precautionar
24. MAW Electrode Hot V Sense Feeder MIG GMAW With Voltage Sensing Wire Feeder Electrode Hot OM 2208 Page 18 4 5 Meter Functions For CC Model NOTE gt The meters display the actual weld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle Meter Reading While Welding V A V A sa 80 0 85 10 3 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Lift Arc TIG 7 0 85 10 3 85 Actual Volts Preset Amps Actual Volts Actual Amps V A V A TIG 85 10 3 85 Blank Preset Amps Actual Volts Actual Amps V A V A Jedi ak 80 0 85 24 5 85 Actual Volts OCV Preset Amps Actual Volts Actual Amps 4 6 Mode Switch Settings For CC Model NOTE gt The Stick modes provide the Adaptive Hot Start feature which automatically increases the output amperage at the start of a weld should the start require it This eliminates electrode sticking at arc start Mode Switch Setting Process Output On Off Control Scratch Start TIG GTAW Electrode Hot Lift Arc TIG GTAW With Lift Arc Start See Section 4 7 Electrode Hot TIG GTAW With HF Unit Pulsing Device Or Remote Control At Remote 14 Stick
25. Stiff SMAW When A Stiff Arc Characteristic Is Desired Electrode Hot Stick Soft SMAW When A Soft Arc Characteristic Is Desired Electrode Hot OM 2208 Page 19 4 7 Lift Arc TIG Procedure I 1 2 1 2 Touch Seconds Do NOT Strike Like A Match With Process Switch in the Lift Arc TIG position start an arc as follows 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work piece at weld start point hold electrode to workpiece for 1 2 seconds and slowly lift electrode An arc will form when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contaminated Ref S 156 279 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance A Disconnect power before maintaining ESP I Maintain more often during severe conditions 3 Months WARNIN KE Replace Repair Or HUE Damaged Or Replace Unreadable Cracked Labels Cables Replace Cracked Torch Body gt Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections
26. TION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION APA Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger som nd fre 4 98 1 1 A identifie un message de s curit particulier Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives I Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le pr sent manuel pour attirer votre attention et identifier les risques champ les pi ces endommag es Entretenir l appareil conform ment de danger Lorsque vous voyez un symbole soyez vigilant et ce manuel suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer e Porter un harnais de s curit quand on travaille en hauteur l information contenue dans les normes de s curit num r es 1 la section 1 4 Veuillez lire et respecter toutes ces normes de Maintenir solidement en
27. ays verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 4 98 e A i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any meta
28. der is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Re LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards y e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards O N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e
29. e 30 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty cla
30. e Switch Settings For CC CV Model 18 4 5 Meter Functions For CC Model oce tn De etie nes deta doe de o gu 19 4 6 Mode Switch Settings For CC Model 19 4 7 Lift Arc TIG Procedure ec coL EUR ELE a ee e ne ER e 20 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 20 5 tRoutine Maintenance s eot center a ee hie cie e tonte de 20 5 2 Voltmeter Ammeter Help Displays 21 5 3 Blowing Out Inside Of Unit 22 5 4 Troubleslhioollng secar biie due nat tt sd 22 SECTION 6 ELECTRICAL DIAGRAMS sssssssee III nnn 24 SECTION 7 PARTS LIST imita er Yer Yu xci a mala EENE 26 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed i
31. e cordon imm diatement s il est gaz hautement toxiques et irritants endommag un c ble d nud peut provoquer une lectrocution e Ne pas souder des m taux munis d un rev tement tels que l acier e Mettre l appareil hors tension quand on ne l utilise pas galvanis plaqu en plomb ou au cadmium moins que le rev te e Ne pas utiliser des c bles us s endommag s de grosseur insuffi ment n ait t enlev dans la zone de soudure que l endroit soit bien sante ou mal piss s ventil et si n cessaire en portant un respirateur alimentation e Ne pas enrouler les c bles autour du corps d air pod tous dd m taux nin elements e Sila pi ce soud e doit tre mise la terre le faire directement avec un peuvenudegager des TumEees toxiques cn eas eg soudage c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine OM 2208 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z8
32. elles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le me
33. ent at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This wa
34. er e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres LES FUM ES ET LES GAZ peuvent moyens isolants suffisamment grands pour emp cher le contact phy tre d sique ventuel avec la pi ce ou la terre etre dangereux e Ne pas se servir de source lectrique courant lectrique dans les zones Le soudage g n re des fum es et des gaz Leur humides dans les endroits confin s ou l o on risque de tomber inhalation peut tre dangereux pour votre sant e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le e Eloigner votre t te des fum es Ne pas respirer proc d de soudage le demande les fum es e Sil utilisation d une source lectrique acourant lectrique s av re n ces e A l int rieur ventiler la zone et ou utiliser un chappement au niveau saire se servir de la fonction de t l commande si l appareil en est quip de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der l instal e Sila ventilation est insuffisante utiliser un respirateur alimenta lation la r paration ou l entretien de l appareil D verrouiller tion d air homologu l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de Se ET xe s curit e Lire les sp cifications de s cur
35. i m a gt 24vac 2200 78 AR M X ARENA TA RSK 1 SY ANT U 115V RMT 25 x x rm D 4 4 2 coNmcroR S RC2 5 Eg gez gE 24V RM 25 8 gt contacTor lt lt RC2 8 A LT K RC2 6 U p gt REFLIN 30 RC2 10 L2 lt lt Rc2 11 U RMT OUT__ 23 lt lt RO2 5 gt XK RC2 3 p gt I0 Z6 02 4 RC1 G U p gt REF COM 22 Ro2 7 RC4 1 gt HSMN 2 ho E G BL RC2 2 E 4 RC4 2 gt K I RC5 1 gt IN cc cv 45 fz gt M gt ET lt RC2 1 EIA RC1 PC3 RC RC2 PLG11 RCA PLG17 RCS PLG18 2 IA lt lt RO2 12 z1 26 NEGATIVE BLACK KK RC2 13 x RC2 14 kk RC2 9 lt RC2 10 lt lt RC9 3 WHT rX RC9 1 BIK I c8 Te 197 550 For 230 460 Volt Models it Diagram Ircul Figure 6 1 C OM 2208 Page 24 L1 197 553 Dep a PASA 1 CRN SRI I To A G o i o T al d ff JI 703 A Lo NT Sl 5 5 5 O LI o T I I I Lt I I C4 2 oL MH 2 T I I PC2 ED RED 31 I RC1 PLG13 se oo REV PISIS n ie RC3 PLG21 I LS TAO AAA TTO lt lt RC3 1 2 lt
36. ick or CC mode is selected on mode switch When set to V A wards minimum short circuit amperage at low arc voltage is the same as normal weld ing amperage When set towards maximum short circuit amperage is increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding see volt ampere curves in Section 2 3 Select setting best suited for application Control adjusts inductance when MIG or V Sense Feeder position is selected on the mode switch Inductance determines the wetness of the weld puddle When set to wards maximum wetness puddle fluidity increases When Pulsed MIG or one of the TIG modes is selected this control is not functional a POWER LIFT ARC IL SCRATCH START TIG TIG V SENSE FEEDER V A ADJUST Y REMOTE V A CONTROL Ref ST 175 086 OM 2208 Page 16 4 2 Front Panel Controls For CC Model 1 Power Switch Lx The fan motor is thermostatically controlled and only runs when cooling is needed 2 Voltmeter see Section 4 5 3 Ammeter see Section 4 5 4 V A Voltage Amperage Adjustment Control 5 Mode Switch The Mode switch setting determines both the process and output On Off control see Sec tion 4 6 Source of control panel or remote for the amount of output is selected on the oN O of V A Control switch For Air Carbon Arc CAC A cutting and gouging place
37. ightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Eq FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2208 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied res
38. im procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International 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 Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of
39. ine fuse s if necessary or reset circuit breaker see Section 3 6 Check for proper input power connections see Section 3 6 No weld output meter display On If using remote control be sure mode switch is in a position that provides output control at Remote 14 receptacle see Section 4 4 or 4 6 as applicable Input voltage outside acceptable range of variation see Section 3 5 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 2 2 If unit contains optional ground current sensor excessive current in the ground circuit may have been detected Have electrician check input power circuit Erratic or improper weld output Use proper size and type of weld cable see Section 3 2 Clean and tighten all weld connections No 115 volts ac output at duplex recep tacle Remote 14 receptacle Reset circuit breaker CB1 see Section 3 4 No 24 volts ac output at Remote 14 re ceptacle Reset circuit breaker CB2 see Section 3 4 OM 2208 Page 22 Notes OM 2208 Page 23 SECTION 6 ELECTRICAL DIAGRAMS L1
40. it des mat riaux MSDSs et les i A instructions du fabricant concernant les m taux les consomma e Installer et mettre la terre correctement cet appareil conform ment bles les rev tements les nettoyants et les d graisseurs son manuel d utilisation et aux codes nationaux provinciaux et i A n x municipaux e Travailler dans un espace ferm seulement S il est bien ventil ou en Ka i ak portant un respirateur alimentation d air Demander toujours un e Toujours v rifier la terre du cordon d alimentation V rifier et s assu surveillant d ment form de se tenir proximit Des fum es et des rer que le fil de terre du cordon d alimentation est bien raccord la gaz de soudage peuvent d placer l air et abaisser le niveau d oxy borne de terre du sectionneur ou que la fiche du cordon est raccord e g ne provoquant des blessures ou des accidents mortels S assu une prise correctement mise la feng ie rer que l air de respiration ne pr sente aucun danger e En effectuant les raccordements d entr e fixer d abord le conducteur e Ne pas souder dans des endroits situ s proximit d op rations de de mise ala terre appropri et contre v rifier les connexions d graissage de nettoyage ou de pulv risation La chaleur et les e V rifier fr quemment le cordon d alimentation pour voir s il n est pas rayons de l arc peuvent r agir en pr sence de vapeurs et former des endommag ou d nud remplacer l
41. l object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary
42. lt RC3 3 c1 1 H e C 2 Wo Ww de ct TI CR1 U Fi ch i els ale cel RIA 222 2 2g 2g PISA A YY y y Y Y Y SE X T2 parne ea A SY 115V RCPT 18V OPTIONAL 3 3 v vy S x 8 9 ORE TER Tonos bl BSS d Y Y 2 2 2 2 RC1 PLG15 2 2 2 2 RC PLGI6 Y Y Y Y V V V V 2 e SES er IE U xa xum SR EIRE A A A AA AA A A R R R KR AI Y AO Gb Ded 1 bte Lei ts es Sale T8 S RC3 8 S y SIN 22 eas S i88 58882 Bp Bee 4 CONTACTOR eee v X Y XO r Xu RC3 1025 I 24V RM 28 8 2 conracron lt lt RC2 8 RC3 4 gt gt L2 lt lt Rc2 6 RC3 2 gt gt j REF IN 30 Le p DEEN A RC2 10 lt Rc2 11 RC1 PLG1 RC6 1 gt gt Lo eg RC2 PLG2 q gt RUT OUT 22 poy 5 i Rex LER RC6 2 gt gt T Pel RGS BLOG RED POSITIVE RC8 1 F gt IADA__ 2 RC2 4 RC1 RCI CONTROL BOARD RP Zi 2 0 1 RCB PLGI p gt REF COM 22 009 7 RC9 PLG19 p AC 1V 10V 29 RC4 1 gt RC8 2 PR BLUE 42 H gt K RC2 9 a E n t o n e 1 ra N o o N N N N o o o o o o o G Re RO2 2 1 Y Y Y Y Y Y Y gt 2 4 RC5 1 gt NEGATIVE K 42 26 PC3 x O RC1 Res E ARE Ale CLEAR 708 RC2 PLG11 RC5 2 gt E iM BLACK 42 RC5 PLG18 RED rh gt SUN io rc WHT SELECT BLK OM 2208 Page 25 For 460 575 Volt Models it Diagram Ircul Figure 6 2 C SECTION 7 PARTS LIST I Hardware is common and not available unless listed WM i 7 ST 801 428 D Figure 7 1 Parts Assembl
43. n Section 1 4 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away IE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Alw
44. pirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylin
45. place tous les panneaux et capots s curit e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal EE L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un dang
46. pletes 115 volts ac CONTACTOR contactor control circuit C Output to remote control O to 10 volts dc 10 volts dc in MIG mode REMOTE D Remote control circuit common OUTPUT q CONTROL E 0 to 10 volts dc input command signal from remote control M CC CV select CC CV models AIV F Current feedback 1 volt dc per 100 amperes AMPERAGE H Voltage feedback 1 volt dc per 10 output recep VOLTAGE tacle volts G Circuit common for 24 and 115 volts ac circuits GND K Chassis common The remaining sockets are not used 3 4 Optional 115 Volts AC Duplex Receptacle And Circuit Breakers U 1 115V 10 A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep tacle see Section 3 3 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects duplex receptacle and 115 volts ac portion of Remote 14 receptacle from overload CB2 protects 24 volts ac portion of Remote 14 receptacle from overload Press button to reset breaker ST 801 245 A OM 2208 Page 13 3 5 Electrical Service Guide A CAUTION INCORRECT INPUT POWER can damage this welding power source This welding pow er source requires a CONTINUOUS supply of 60 Hz 210926 power at 10 of rated input voltage Do not use a generator with automatic idle device that idles engine when no load is sensed to supply input power to
47. pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 2208 Page 7 1 4 Principales no
48. rmes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de so
49. rranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 7 00 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment sovice and Mapai Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone
50. s e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage 43 d DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appa reil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des Sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage
51. this welding power source NOTE Cr Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available Three Phase Single Phase Input Voltage 230 460 575 230 460 Input Amperes At Rated Output 30 5 18 9 15 2 47 4 24 5 ae edd Standard Fuse Or Circuit Breaker Rating In Am 45 25 20 70 35 Reference 1996 National Electrical Code NEC S 0092J OM 2208 Page 14 3 6 Connecting Input Power gt Check input voltage available at E site I The Auto Link circuitry in this unit automatically links the power source to the primary voltage being applied A 1 P 230 460 unit can be connected to either 230 or 460 VAC input power A 460 575 model can be connected to either 460 or 575 VAC input power L 1 Input And Grounding Conductors 2 Line Disconnect Device See Section 3 5 toi 2 For single phase operation n 3 Black And White Input Conductor men 4 Red Input Conductor 5 Insulation Sleeving O 6 Electrical Tape L1 Insulate and isolate red conductor L2 as shown A Always connect green wire to supply grounding termi red wires L1 L2 L3 to line terminals nal never to a line terminal x Connect black white and
52. timulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INTRODUCTION 2 1 Specifications RMS Amps Input at Rated Load Output 60 Hz 3 Phase at NEMA Load Voltage Amperage Max Open Voltages and Class Rating Rated Output at Range in Range in Circuit 60 Duty Cycle CV Mode CC Mode Voltage 230 V 460 V 575 V KVA KW 300 A at 32 VDC 3 Phase 10 35 V 5 400A 90 VDC 30 5 18 9 15 2 12 2 11 6 0 21 0 10 0 08 0 09 0 04 225 A at 29 VDC 1 Phase 47 4 24 5 11 3 7 6 0 34 0 14 0 09 0 04 While idling See Section 3 5 for additional information 2 2 Duty Cycle And Overheating 500 Duty Cycle is percentage of 10 min utes that unit can weld at rated load 400 without overheating d If unit overheats output stops a ty 300 Help message is displayed m p g played see S 250 3 PHASE Section 5 2 and cooling fan runs lt 225 OPERATION Wait fifteen minutes for unit to cool 2 200 SINGLE Reduce amperage or voltage or o PHASE duty cycle before welding z OPERATION A Exceeding duty cycle can damage unit and void warranty 100 10 15 20 25 30 40 50 60 70 80 90 100 XDUTY CYCLE 60 Duty Cycle zm 6 Minutes Welding 4 Minutes Resting Overheating Aor V T
53. tional Fire Protection Association Batterymarch Park Quincy MA 02269 OM 2208 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 2208 Page 4 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 SEC
54. udage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 2208 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un s
55. ulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 2208 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz Sous haute pression Si une bouteille est endomma g e elle peut exploser
56. y OM 2208 Page 26 Item Dia Part No Mkgs No Description Quantity Figure 7 1 Parts Assembly cc MEE 1175 148 WBRAPPER i zo teen oa ECRANS ede ts A PA ee 178551 INSULATOR side LH 2 ETE RP Ne Gates 175256 INSULATOR side RH 2 ia etra 195 585 HANDLE oracion mis ina pare io A OS uelRerp Webster 138 442 LABEL caution falling equipment Are HD1 189 567 TRANSDUCER current 300A P ael sie a s PLG9 180 204 CONNECTOR amp PINS MC 194546 BUS BAR lem s Doors eec 175 139 BUS BAR output rectifier T a Ree d A SEA 181 853 INSULATOR screw O ri D1 2 179 630 KIT DIODE ultra fast recovery TE DER 179 276 BUSHING snap in nyl 1 000 ID x 1 375mtg hole 10 C5 6 R1 175 194 RESISTOR CAPACITOR 0 000 es n 11 RT1 2 173632 THERMISTOR NTC 30K ohm v cbe epi Ex 185835 LABEL warning exploding parts ul m ed Aat 183 551 WINDTUNNEL LH craro iei aiaia SCG ER ees NL 604 176 RECEPTACLE str dx grd 2P3W 15A 1
57. y label the label should also be ordered Part of 043 302 115V Aux Power Option 230 460 or 043 303 115V Aux Power Option 460 575 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2208 Page 27 Item Dia Part No Mkgs No Description Quantity Figure 7 1 Parts Assembly Continued 36 C34 192 935 CAPACITOR elctlt 2700uf 450VDC 230 460 2 2930 us C34 193 738 CAPACITOR elctlt 1800uf 500VDV 460 575 2 Y kazala PC2 197 585 CIRCUIT CARD interconnect 230 460 1 SN PC2 197 586 CIRCUIT CARD interconnect 460 575 1 TE PLG13 131204 CONNECTOR 8 SOCKETS RC13 1 EE PLG14 21 115093 CONNECTOR 8 SOCKETS RC14 RC21 2 Miscou ee ue Rose ns does Ivi 126 026 LABEL warning electric shock d PK aid altea 175140 BRACKET DI DT 1 ADO ARC omine 175482 4 COIE DVD oro AAA lea an RO RR 2 22540 e oe Ga N 109 056 GORE eek ee Ra A ee pr ue hsec 2 RE SR1 179 629 KIT DIODE power module 1 42 PM1 2 180110 KIT transistor IGBT module
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