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1. sseese eens 1 Tipp 215 980 BUSHING strain relief 709 984 id x1 375 mtg hole 1 icum eer re nee 215982 CABLE DOWGI ui Er surda dp aos Huit titi eat side eau Al sense Laeta Ch di ne M EE PLATE ident rear order by model and serial number 1 A na eee 217 297 COVER receptacle weatherproof duplex rcpt 1 K PME OS eue ISSO BOX lee Cli eu acura Re PME TIT 2 DOO wutadsae dut vas 148 329 LABEL caution incorrect voltage 230 460 1 zio PR sale 182 227 LABEL caution incorrect voltage 460 575 1 EDU ne ee a 192 853 BRACKET mtg contactor capacitor PC Board 1 HD ie PC 213 664 CIRCUIT CARD control 230 460 1 este POT avs 215045 CIRCUIT CARD control 460 575 1 T PLG2 131056 CONNECTOR SOCKETS RC2 1 DES PLG3 130 203 CONNECTOR SOCKETS RC3 l ie PLG4 115094 CONNECTOR SOCKETS RC4 1 DS PLG5 115091 CONNECTOR SOCKETS ROD l IET PLG7 115093 CONNECTOR SOCKETS RC7 L1 26 RC10 166 679 CONNECTOR amp SOCKETS 1 er W1 2 211 493 CONTACTOR def prp 40a 8p dual 24vac coil w
2. 209 219 RECEPTACLE twlk insul fem Tweco 2 UD Led ee ae ee eee ree eee NAMEPLATE order by model and serial number 1 m Pp a aoa RS 174 992 4 ANOS pointer 640 sc ies eater e o x SCR ce ore town daw dads 2 Os do 175855 e DOOR MONL 2522 ia trace ome CR eet a CS A See du 1 E E PER P 174991 KNOB pointer 1 250 2 MEO ERE 176 226 INSULATOR switch power 1 64 y O 128 756 SWITCH tgl 3PST 40A 600VAC 1 TI A sens 134327 LABEL warning general precautionary 2 Bi ni E es 199 840 BUS BAR diode 2 Xl Gv PCT TER 190 125 LABEL warning electric shock power cord 1 When ordering a component o alhally displaying a precautionary label the label should also be ordered Part of 195 181 Tweco Connector Option 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 Page 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 replacemen
3. 3 the reasonable cost of repair or replacement 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 limitat
4. 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 Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI 749 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 glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection T 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to ad
5. Figure 8 1 Parts Assembly Continued TES o RONDE 23 4 sis 192 935 CAPACITOR elctlt 2700uf 450VDC 230 460 2 TES o C3 4 206 756 KIT capacitor elctlt replacement Includes 1 Eee du cca c E ruat 193 738 CAPACITOR elctlt 1800 UF 500 VDC 2 Aig asia Mahe Ogee apa RA 217040 NUT nylon m12 thread capacitor mounting 2 OT et PC2 209 579 CIRCUIT CARD interconnect 230 460 1 o eee PC2 208 783 CIRCUIT CARD interconnect 460 575 1 ART Te PLG13 131 204 CONNECTOR SOCKETS RC13 1 Here PLG14 21 115093 CONNECTOR amp SOCKETS RC14 RC21 2 PR ne 126 026 LABEL warning electric shock 1 ie OOM a Bea aan Tire 175140 2 BRACKET DT 3n sedis dee tev ns adel baila ered ha e Xr is oen 1 mo 5 ati Ges pene ae 179 482 z COIE DUDT 2 tol oii da eerste aan Re EE PEE 2 Ur 109056 ec C M 2 TM MT SR1 179629 KIT DIODE power module 1 42 PM1 2 208173 KIT transistor IGBT module 1 peu ocio A s 173670 2s STABILIZER o ne eto ENSE ane s e oo fac etas cad 1 44 By EN 173563 2 INDUCTOR INPUT 33 3 x 3 Gotti ce rede ORC de e estacion 1 potus ED
6. de s curit de Californie chapitre 25249 5 et suivants procr ation Se laver les mains apr s manipulation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de
7. 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 4 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 10 power at 10 of rated input voltage Phase to ground voltage shall not exceed 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 this welding power source 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 60 Hz Three Phase 69 ds ane Input Voltage 230 460 575 230 460 Input Amperes At Rated Output 31 15 12 53 27 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 35 15 15 60 30 Normal Operating 3 45 20 20 80 40 Min Input Conductor Size In AWG4 10 14 14 8 10 Max Recommended Input Conductor Length In Feet Meters a A ES s oe a Min Grounding Conductor Size In AWG4 10 14 14 8 10 Reference 2003 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 6
8. Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 10 Overcurrent Protection Select type and size of overcurrent protection using Section 4 5 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout de vice and place switch in the On posi tion 2 04 Ref 802 136 A 801 192 OM 2208 Page 15 4 7 Connecting 3 Phase Input Power GND PE Earth Ground Tools Needed E _ OM 2208 Page 16 A Installation must meet all National and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in put power before connecting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal C7 The Auto Link circuitry in this unit au tomatically links the power source to the primary voltage being applied A 230 460 unit can be connected to ei ther 230 or 460 VAC input power A 460 575 model can be connected to either 460 or 575 VAC input power For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L
9. N N V V V CBI 1 gt 115VAC 21 Aca 24VAC 19 18 E E A DEM xa x VS i a S a NNN NNN A A NN A T TIY o md ded YT 1 115V RMT 25 KR KR Nom Q Q n wo d 2 GONTACTOR S eee amp ee amp 2 ere 24V RMT 28 ak B gt Sontacrar lt lt RO2 8 F RC3 4 lt RCZ 6 H l REF IN 30 a E E DEIN 2 RC2 10 SRE RC1 PLO1 RC2 5 PLG2 7 RMT OUT 23 RC3 PLG3 7 HD1 C gt OX RC2 3 PC1 RC4 PLG4 RC6 2 gt ROS PLeS pep POSITIVE c WOON ec RG RC CONTROL BOARD RC PLG7 Arte 2P O l RC8 PLGB p gt REF COM 22 7 RC9 PLG19 Br RC8 2 gt 42 H gt Who E RC2 9 v E M t o OR BLUE A gt oo o o O O o a G c K e amp tr K G 4 RC2 2 V V V NNN N 4 NEGATIVE K 42 26 PC3 O RCI RC C8 RC2 PLG11 RC5 2 gt RC4 PLG17 42 RC5 PLG18 WHT CC CV 43 M PONT EE RC2 1 t Diagram For 460 575 Volt Models Ircul Figure 7 2 C OM 2208 Page 25 SECTION 8 PARTS LIST ICS Hardware is common and not available unless listed 801 428 H Figure 8 1 Parts Assembly OM 2208 Page 26 Item Dia Part No Mkgs No Description Figure 8 1 Parts Assembly Quantity en ie T 17952149 c A umo am reddit ice tant A d e 178551 INSULATOR side LH A ELT 175 256 INSULATOR Side HE 42 ina ide pte Re Ro ane et acid cl ios T quu TTD 195 585 6 PANDLE lt is coc iu aln td rdc tt o E coe We der retards eo ee ee Las 138 44
10. Switch The Mode switch setting determines both the process and output On Off control see Sec tion 5 6 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 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 amperageis increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding see volt ampere curves in Section 3 3 Select setting best suited for application When a TIG process is selected on the mode switch this control is not functional V A ADJUST POWER OM 2208 Page 18 LIFT ARC TIG p SCRATCH START TIG STICK asn D v REMOTE V A CONTR Ref ST 175 500 5 3 Meter Functions For CC CV Model The meters display the actual weld output values for approximately three seconds after th
11. a current density of at least 300 circular mils per ampere mm for metric use S 0007 F For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 OM 2208 Page 12 4 3 Remote 14 Receptacle Information LA remore 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 115 volts ac Protected by circuit breaker CB1 OUTPUT J Contact closure to completes 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 CONTROL E 0 to 10 volts dc input command signal from remote control M CC CV select CC CV models F Current feedback 1 volt dc per 100 amperes A N T p p 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 4 4 Optional 115 Volts AC Duplex Receptacle And Circuit Breakers m 1 115V 10A AC Receptacle Power is shared between duplex receptacle and Remote 14 recep tacle see Section 4 3 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects duplex receptacle and 115 volts ac portion of Remote
12. crans lat raux ou un cran facial OM 2208 Page 6 que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant d
13. en bon tat R parer ou remplacer sur le 0 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut e Porter un harnais de s curit si l on doit travailler au dessus du sol Provoquer ugs ace dents moles ou dec Prud rs e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est BED TPR aedes R S d sous tension lorsque le courant est d livr la PES ui sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le cable de retour de fa on obtenir un bon contact metal metal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique a la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol en u
14. falling e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 Owners Manual and national state and local codes e Always 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 Frequ
15. interl 230 460 only 1 TERT INCIDUN NUNT 173763 STAND OFF No 10 32 x 1 418 230 460 only 8 Eo MN I een 201 684 TRANSFORMER control 230 460 0 cee eee 1 20 ios T2 193 774 TRANSFORMER control 230 460 1 la aria bat 183 549 BRACKET mtg aux transformer 7 Eo de 12 22 204 256 TRANSFORMER control 460 575 1 BO i era den 207 127 4 WNINDTUNNEL BEL 1392 pie in ote Me Mi eee eue 1 Lei ous 153 403 BUSHING snap in nyl 750 ID x 1 000mtg 2 dor MM eee ae 177 547 BUSHING snap in nyl 1 125mtg 1 576 NM CT1 175199 TRANSFORMER current 1 L pi Joe 025 248 STAND OFF GSU Guias dd ae detente d eet 2 Societe Ol saias 186 015 CAPACITOR polyp film 34uf 1000VAC 230 460 1 DO tir OI stake 193 858 CAPACITOR polyp film 27uf 1000VAC 460 575 1 When ordering a component ala displaying a precautionary label the label should also be ordered Part of 043 302 115V Aux Power Option 230 460 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
16. lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling OM 2208 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 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 r
17. m Miller 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp 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 manufacturer s warranty if any 3 Equipmentthat 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
18. ones death ded deserit 207 725 HEAT SINK power module 1 46 t su 173811 TRANSFORMER HF 230 460 1 46 diese 180 952 TRANSFORMER HF 460 575 1 ARA 207 467 V AEAT SINK Tec A A 1 et AMA 175 255 INSULATOR rectifier ci oui s a tien 1 O eee 110386 RELAY 24VAC 460 575 only 1 YA nr 173693 s FOOT MI Bl 531 1m ak dee odio eR a qe en ase donc oma backs 4 Rs Ohad seth doe cu det fae 170 796 su SCREW MIO TOOL os Dia racio Dean va ees awe ae AA 4 eo A see 175182 BASE quimera cala ek d og o dud Cane in 1 OA POS vs 222 914 CIRCUIT CARD front panel display CC model 1 E lt PS POS iss 219 820 CIRCUIT CARD front panel display CC CV model 1 Tc PLG11 115091 CONNECTOR amp SOCKETS RC2 1 O N FM 175084 MOTOR fan 24VDC 3000RPM 1 54 RC1 185 730 RECEPTACLE w leads amp plug 1 ao oe eee ee EN 178548 TERMINAL connector friction 2 ju DOC AE C7 8 222408 a CAPACITOR ASSY iii dde Rene desde ed ol 2 A ger aus rae 185 732 PANEL TON od ein he ee ea ee eo eee ee ad 1 E S Se dou ire 129 525 RECEPTACLE twlk insul fem 2 JO Lots
19. pose de protec teurs dans la zone de travail Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation OM 2208 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Saf
20. utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort instructions aff rentes pour viter tout risque Les instructions en e l quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Nepas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s raie e de dans la Section 2 5 Lireet amp Ne pas enrouler les c bles autour du corps ae pa l e Sila pi ce soud e doit tre mise la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en x 3 m me temps cause de la pr sence d une tension vide doubl e E UNE DECHARGE ELECTRIQUE peut e N utiiser qu un mat riel
21. 0 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Notes OM 2208 Page 14 4 6 Connecting 1 Phase Input Power ES 2 p EE W N N 8 E GND PE li Earth E PEN Ground 0 10 RA SS X cme Tools Needed E gt Installation must meet all Na tional and Local Codes have only qualified persons make this installation Disconnect and lockout tag out input power before con necting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line termi nal C7 The Auto Link circuitry in this unit automatically links the power source to the primary voltage be ing applied A 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 1 Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Green Or Green Yellow Grounding Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolate red conductor as shown 6 Input Power Cord 7 Disconnect Device switch shown in the OFF position 8 Disconnect
22. 1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Overcurrent Protection Select type and size of overcurrent protec tion using Section 4 5 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 2 04 Ref 802 136 A 801 192 SECTION 5 OPERATION 5 1 Front Panel Controls For CC CV Model 1 Power Switch The fan motor is thermostatically controlled and only runs when cooling is needed 2 Voltmeter see Section 5 3 3 Ammeter see Section 5 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 5 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 y DOG 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 Adjus
23. 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 5 400 A 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 4 5 for additional information 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats output stops a 3 PHASE amp 460VAC Help message is displayed see SINGLE PHASE OPERATION Section 6 2 and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding WELDING AMPERES Exceeding duty cycle can damage unit and void 40 50 60 70 80 90 100 warranty DUTY CYCLE 60 Duty Cycle 4 Minutes Resting Overheating pm A or V m A Minutes Reduce Duty Cycle sduty1 5 95 SA 207 877 OM 2208 Page 9 3 3 Volt Ampere Curves A CC Mode AK CONTROL AMPERAGE B CV Mode 200 400 AMPERAGE OM 2208 Page 10 Volt ampere curves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curves s
24. 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les cables ensemble en les tordant ou en les enveloppant 2 Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 INTRODUCTION 3
25. 2 LABEL caution falling equipment Aie HD1 182918 TRANSDUCER current 400A NW TEM 203 342 BUS BAR current sensor BE lt vies UE 203 341 BUS BAR output rectifier NC pina TT TT 1981853 INSULATOR SCrEW d ccs RSR ed tai d ee at qe Roe e neue Oi ds 2172 ues 201531 KIT diode power module 2 c 179 276 BUSHING snap in nyl 1 000 ID x 1 375mtg hole 2 10 C5 6 H1 175 194 RESISTOR CAPACITOR os toas lem dee te cm Roe dee 1 11 HT1 2 173632 THERMISTOR NTC 30K ohm 2 Vadis gute patet at end ud 185 835 LABEL warning exploding parts 2 v e PR ie te ak 183 551 WINDTUNNEL LH 25 3 gd ood da o o ERR ees 1 sud d cci eee 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 Lore e ue ae 182 445 NUT T 000NDPT oes nudes Seek heralds in ta essi eod eoe dide ea on 1 NECEM CBI ire 089 807 CIRCUIT BREAKER man reset 1P 2 5A 250VAC 1 us MO ane CB1 083 432 CIRCUIT BREAKER man reset 1P 10A 250VAC 1 p i ee eee CB2 083 432 CIRCUIT BREAKER man reset 1P 10A 250VAC 1 Ar 206 460 PANEL atre ue A Re RC RO ECRIRE ef PO Ran 1 uu PO 175147 PANEL rear w aux power
26. 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 6 3 Blowing Out Inside Of Unit 6 4 Troubleshooting 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 Trouble Remedy No weld output unit completely inop erative Place line disconnect switch in On position see Sections 4 6 and 4 7 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 6 and 4 7 Check for proper input power connections see Section 4 6 and 4 7 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 5 4 or 5 6 as applicable Input voltage outside acceptable range of variation see Section 4 5 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 3 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
27. A 17 5 1 Front Panel Controls For CC CV Model nanana 17 5 2 Front Panel Controls For CC Model anaana 18 5 3 Meter Functions For CC OV Model 44 44 4 8 19 5 4 Mode Switch Settings For CC CV Model 19 5 5 Meter Functions For GO Model sus dun wane Roc ode sca ce Rao sto oe sco ace al eee UR ed 20 5 6 Mode Switch Settings For CC Model s anaana nannaa 20 5 7 LIAT TIG Proc dure x tc actin axes qoc d oe icto aon SO Eoo e UR oy B ec dea di a d e oen 21 SECTION 6 MAINTENANCE amp TROUBLESHOOTING eeseeee nnn 21 6 1 Routine Maintenance wisc atar a Aa vas aaa 21 6 2 Voltmeter Ammeter Help Displays mn 22 6 32 Blowing Out Inside OEUNIR a nee ita tu s x n Re ERE Ue S e ana Vp PEE d Y EPOR 23 o4 TProbleshoollg genier uet bere crt ER tame cre oe es Pedir ptt edad ba teque atte d 23 SECTION 7 ELECTRICAL DIAGRAMS oir ntm hee xu no n Qr e d eur 24 SECTIONS PARIS LIST Ta DOR en drain dre TRU Ee MU a UE A os a Us re a e ie ot 26 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _3 05 Warning Protect yourself and others from injury read and follow these precautions 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 adj
28. G19 TP1 PLG20 lt RC9 1 lt RC9 3 WHT BLK Je i Je e 1 N Q a V lt RCI 3 lt RCI 4 WHT RC5 1 gt RC5 6 gt lt RC2 13 lt RC2 14 T1 1 Q U engine before servicing e Do not operate with covers removed e Have only qualified persons install v i o L L be 4 o o o o O a gt o c o a e e Disconnect input power or stop WARNING use or service this unit ELECTRIC SHOCK HAZARD POSITIVE NEGATIVE O CB 197 550 B t Diagram For 230 460 Volt Models Ircul Figure 7 1 C OM 2208 Page 24 197 553 B L1 1 L1 2 J2 1 J2 2 J1 1 J1 2 N noort c GL 12 02707 UD Z PIE 3 22 Eo RED 3 RC1 PLG13 Tic y RC2 PLG14 y RO3 PLG21 T PC2 onc SO es ES or GAN VEL l esc dou C3 T O o Q BES use or service this unit engine before servicing e Do not operate with covers removed e Have only qualified persons install C1 o a a a b p O 2 o 2 X o o pd o c o a e e Disconnect input power or stop 4 Y m Y 7 9 ROO A e e Q a d PLC10 VV UV g Ec N r 2 od a E v Y Il ON S S isi T m 5 His A Ge OZ EE mda eer ae l II eL LL x I E I Il 0 WO TN 24V a I 3 o y x M amp Q S PLG10 _ _ 12 11 10 7 8 9 di P 1 y T ja 555 5 555 c c 1 4 c x cc 20 42 M NME
29. OM 2208 175 493AF May 2005 2 Multiprocess Welding K Description E KJ a Es Arc Welding Power Source XMT 304 230 460 And 460 575 Volt Models A IS X li D SS CC CV and CC Models Visit our website at OWN E R S MAN UAL www MillerWelds com in From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s 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 couldn t 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 They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir Y E BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They LUE El jue ere ex e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper ma
30. P meta enano oreilles si le niveau sonore est trop lev e Des tincelles et des mat riaux chauds du soudage peuvent an passer dans d autres zones en traversant de petites issures et des ouvertures e Afin d liminer tout risque de feu tre vigilant et garder toujours un LES BOUTEILLES peuvent exploser extincteur la port e de main si elles sont endommagees e Le soudage effectu sur un plafond plancher paroi ou s paration D s bouts d Gaz porci comenencia peut d clencher un incendie de l autre cote sous haute eso Si une bouteille est e e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des g e elle peut exploser Du fait que les bouteilles de r servoirs tambours ou conduites a moins qu ils n aient ete prepa gaz font normalement partie du proc d de soudage res Re conform ment a AWS F4 1 voir les normes de les manipuler avec pr caution s curit e Brancherle c ble de masse sur la pi ce le plus pr s possible de la e Prot ger les bouteilles de gaz comprim d une chaleur excessi zone de soudage pour viter le transport du courant sur une longue ve des chocs m caniques des dommages physiques du lai distance par des chemins inconnus ventuels en provoquant des tier des flammes ouvertes des tincelles et des arcs risques d lectrocution d tincelles et d incendie e Placer les bouteilles debout en les fixant dans un support sta e Ne pas utiliser le poste de soudage pour d geler des
31. VANT UTILISATION 5 2 1 Signification des symboles us pac ira bcd rd e oodd dd os ee dete pelos ana 5 2 2 Dangers relatifs au soudage l arc annann narn n erae 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de S curit s SR faute ain ees Glan SCRAC au mt aO e o ER IE e IN a 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 INTRODUCTION au 22 achats aba Rr RRERK Ra ku E ESZ Ue ERU alab 9 Sl SDOCIHCdlgIiS asia D aaa 9 3 2 Duly Cycle nd Overhsalltig senis aem a oe ane qr Ateste fused doo watt AE eus 9 93 9 VOll AMpele GUIVES 2 mans AA A Din dabo ID ene e MEER aT 10 SECTION 4 INSTALLATION corras o E amus Ya oq ES me eR E Ronde teen esse 11 4 1 Selecig a Locallol 3 435 3 9 D aee beet Le pe Hato pc eR E aS Patti ases Bird a dpa es 11 4 2 Weld Output Receptacles And Selecting Cable Sizes nananana 12 4 3 Remote 14 Receptacle Information mmn 13 4 4 Optional 115 Volts AC Duplex Receptacle And Circuit Breakers 13 4 5 Electrical Service QUIAS aer de RTS RIA ES YA EN EE SE eee eR E Tas 14 4 6 Connecting 1 Phase Input Power ehh hr rns 15 4 7 Connecting 3 Phase Input Power hr 16 SECTION 5 OPERATION x29 5 rese xti OO ee eae teens wi ER E E E oe E S
32. ause severe burns Do not touch hot parts bare handed e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e 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 physical damage 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 aw
33. ay from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit HE FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit 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 MOVING PARTS can cause injury e Keep away from m
34. ces phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body B m m 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 before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som _3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes TN zf Ce groupe de symboles signifie Avertissement Attention Risques 2 1 i Symboles utilis s Symbole graphique d avertissement Attention Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints A Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures a prendre pour supprimer S Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont
35. conduites tionnaire ou dans un porte bouteilles pour les emp cher de tom gel es ber ou de se renverser e Encas de non utilisation enlever la baguette d lectrode du porte e Tenirles bouteilles loign es des circuits de soudage ou autres lectrode ou couper le fil la pointe de contact circuits lectriques e Porter des v tements de protection exempts d huile tels que des e Ne jamais placer une torche de soudage sur une bouteille gaz gants en cuir une veste r sistante des pantalons sans revers des e Une lectrode de soudage ne doit jamais entrer en contact avec bottes et un casque une bouteille e Avant de souder retirer toute substance combustible de ses poches e Ne jamais souder une bouteille pressuris e risque d explosion telles qu un allumeur au butane ou des allumettes e Utiliser seulement des bouteilles de gaz protecteur r gulateurs e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B tuyaux et raccords convenables pour cette application sp cifi wa pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec
36. d Circuit T D Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Turn off power before Weldi 10 60 60 100 e weld out hes a 2 Duty Duty 10 100 Duty Cycle EE taat P Cycle Cycle 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 0 120 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 Odor oa 2 ea 2 0 2ea 3 0 2 ea 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 2 ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 2 ea 2 0 2ea 3 0 2ea 4 0 3ea 3 0 3 ea 4 0 3 ea 4 0 600 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or
37. e arc is broken Mode Meter Reading At Idle Meter Reading While Welding V A V A Sarre Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Actual Volts Preset Amps Actual Volts Actual Amps V A V A Blank Preset Amps Actual Volts Actual Amps V A V A Preset Volts Blank Actual Volts Actual Amps V A V A MIG Pulse Display Pulse Display Actual Volts Actual Amps V A V A cc mum Blank Preset Amps Actual Volts Actual Amps V A V A Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Feeder NEN Flashes OCV And Preset Blank Actual Volts Actual Amps 5 4 Mode Switch Settings For CC CV Model 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 5 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 SMAW Electrode Hot V Sense Feeder MIG GMAW With Voltage Sensing Wire Feeder Electrode Hot OM 2208 Page 19 5 5 Meter Functions For CC Model The meters display the actual we
38. e 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 Do NOT Strike Like A Match Ref S 156 279 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect power Maintain more often before maintaining during severe conditions 3 Months Replace 2 Repair Or Damaged Or EA A Replace Replace sie Unreadable XO Cracked orch Body Labels 6 Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections 6 Months o P d Blow Out Inside 4 OM 2208 Page 21 6 2 Voltmeter Ammeter Help Displays CS 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 sh
39. ently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill 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 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 If 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 Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present 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 e 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 metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e Turn Off inverter discon
40. es fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes PC DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage lm 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et
41. esearch 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 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 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 02269 9101 phone 617 770 3000 website www nfpa 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 there are 10 Regional Offi
42. ety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magnetiques et lectriques Le courant de soudage pendant son passage dans les cables de souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin 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 Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques 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 conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 2208 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87
43. faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation 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 un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiler ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement 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 Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la
44. hown va curve1 4 95 SA 178 652 SA 178 653 SECTION 4 INSTALLATION 4 1 Selecting a Location Dimensions And Weight 76 Ib 34 6 kg Movement 1 Lifting Handles Use handles to lift unit 2 Hand Cart Do not move or operate unit M 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 power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location 4 INPUT SERIAL NO STOCK NO VOLTS AMPERES KW PHASE loc_2 3 96 Ref ST 151 556 ST 801 192 OM 2208 Page 11 4 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 Wel
45. intenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in EGN oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided 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 specification 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 7 Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MPSS AO O ae ae Rae ae ee hae tad li ie ane een ade eae 1 162 Are Welding Hazardo 2 Te kaa Ae de a nue alee deu aie ee A qua 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings aaae 3 1 5 Principal Safety Standards ces uma de pieced cech c RD c o S cio Dodo ate ND A 4 156 EDF TORAH OM asser oes td b oe rar Siem ah a b do Dea Ee V d a ir 4 SECTION 2 CONSIGNES DE S CURIT LIRE A
46. ion or exclusion may not apply to you This warranty 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 1 05 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 Contact 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 Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s T
47. jacent areas e 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 sparks 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 e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E 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 respirator HOT PARTS can c
48. ld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle Meter Reading While Welding V A V A San TG Actual Volts OCV Preset Amps Actual Volts Actual Amps V A V A Actual Volts Preset Amps Actual Volts Actual Amps V A V A Blank Preset Amps Actual Volts Actual Amps V A V A su Or So Actual Volts OCV Preset Amps Actual Volts Actual Amps 5 6 Mode Switch Settings For CC Model 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 5 7 Electrode Hot TIG GTAW With HF Unit Pulsing Device Or Remote Control At Remote 14 Stick Stiff SMAW When A Stiff Arc Characteristic Is Desired Electrode Hot otick Soft SMAW When A Soft Arc Characteristic Is Desired Electrode Hot OM 2208 Page 20 5 7 Lift Arc TIG Procedure 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 1 2 Seconds Normal open circuit voltag
49. nect 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 e lfinside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s 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 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
50. oining symbols CS Means Note not safety related 1 2 Arc Welding Hazards 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 in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away m 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
51. oquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent e Ne pas toucher aux pi ces chaudes utiliser les outils recom mandes et porter des gants de soudage et des v tements pais pour viter les br lures LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester distance provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologuees de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut e Ne pas souder dans un endroit o des tincelles peuvent tomber sur des des substances inflammables affecter louie e Se prot ger ainsi que toute autre personne travaillant sur les lieux e Porter des protections approuv es pour les conte d S Sune GS GL
52. oving 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 Do not point gun toward any part of the body other people or any metal when threading welding wire E 3 1 4 California Proposition 65 Warnings STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts 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 Keep high frequency source doors and panels tightly shut kee
53. own 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 OM 2208 Page 22 I Ti P 1 P 2 P 3 P 4 A 9 10 L fan to cool it see Section 3 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 3 2 Operation will continue when the unit has cooled 7 Help 6 Display Indicates that the input 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 1596 below the applicable input voltage If this display is HE L HE L HE L NHE lt lt Hi Hi HE L P 5 T 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 1596 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
54. p 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 lf 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 A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm gt Battery posts terminals and related accessories contain lead and
55. position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur e Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxygene provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s cu
56. ransportation Department PRINTED IN USA 2005 Miller Electric Mfg Co 1 05 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller
57. red 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 Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HE Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks 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 one year whichever is greater
58. rit respiration ne pr sente aucun danger l e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute zl E ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne vanis plaqu en plomb ou au cadmium moins que le rev tement n ait de terre du sectionneur ou que la fiche du cordon est raccord e une t enlev dans la zone de soudure que l endroit soit bien ventil et en prise correctement mise la terre portant un respirateur alimentation d air Les rev tements et tous les e En effectuant les raccordements d entr e fixer d abord le conducteur m taux renfermant ces l ments peuvent d gager des fum es toxi de mise la terre appropri et contre v rifier les connexions ques en cas de soudage OM 2208 Page 5 LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et a la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles in
59. t 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 Effective January 1 2005 Equipment with a serial number preface of LF 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 claim 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 delive
60. t 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 Stick or CC mode is selected on mode switch When set to wards minimum short circuit amperage at low arc voltage is the same as normal weld ing amperage When set towards maximum short circuit amperageis increased at low arc voltage to assist with arc starts as well as reduce stick ing while welding See volt ampere curves in Section 3 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 POWER LIFT ARC TIG 19 SCRATCH START TIG PULSED MIG CC MIG TIG SF GE STICK V SENSE FEEDER V A ADJUST e REMOTE V A CONTROL Ref ST 175 086 OM 2208 Page 17 5 2 Front Panel Controls For CC Model 1 Power Switch The fan motor is thermostatically controlled and only runs when cooling is needed 2 Voltmeter see Section 5 5 3 Ammeter see Section 5 5 4 V A Voltage Amperage Adjustment Control 5 Mode
61. tenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage LES ACCUMULATIONS DE GAZ risquent 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 confi n s ou se servir d un respirateur d adduction e Porter un casque de soudage approuv muni de verres filtrants ap d air homologu propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous vo DES PI CES CHAUDES peuvent EE l provoquer des br lures graves e Avoir recours des crans protecteurs ou a des rideaux pour prot ger les autres contre les rayonnements les blouissements et e Ne pas toucher des parties chaudes mains les tincelles pr venir toute personne sur les lieux de ne pas nues regarder l arc e Pr voir une p riode de refroidissement avant e Porter des v tements confectionn s avec des mati res r sistantes d utiliser le pistolet ou la torche et ignifuges cuir coton lourd ou laine et des bottes de protection AYIA LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut prov
62. tilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber LES FUM ES ET LES GAZ peuvent e Se servir d une source lectrique courant lectrique UNIQUEMENT si etre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n Le soudage g n re des fum es et des gaz Leur cessaire se servir de la fonction de t l commande si l appareil en est inhalation peut tre dangereuse pour la sant quip e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e Alint rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de sols grilles ou chafaudages en
63. weld cable see Section 4 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 4 4 No 24 volts ac output at Remote 14 re ceptacle Reset circuit breaker CB2 see Section 4 4 OM 2208 Page 23 GCS OPTION b l l 47 Ma uM 2 TURN I REED I DN J R a eG AE E ETES CAN YEL d T NE o T NELI 9 i2 Tc MT 2 SIMI I L3 AED e FED 3 s1 I 115V RCPT OPTIONAL J gt 115V RMT 75 CONTACTOR 24V RMT ZI lt Derr CONTACTOR RES p REF IN 30 RC2 10 c gt RMT OUT 255 RC2 3 Fp MOA E cog RCA g l p EE COM 271 2 7 H gt 1V 10V 29 lt RC2 9 6 PL RC2 2 K SECTION 7 ELECTRICAL DIAGRAMS CC CV 43 gt M SELECT S PC3 RC1 FRONT PANEL BOARD RC1 RC2 PLG1 1 RC4 PLG17 RC5 PLG18 lt RC1 2 lt RCI 3 lt RCI 1 lt RCI 1 ALK I J4 RC7 4 gt RC7 5 gt RC7 1 gt RC5 2 gt 3 RC2 12 Wi W2 L1 1 L1 2 PC2 INTERCONNECT BOARD RC1 PLG13 RC2 PLG1 4 RC3 PLG21 L5 L3 2 PC4 RC1 PLG15 lt RCI 2 lt RCI 1 lt RCI 3 lt RCI 4 RCI 2 Y Pd La Ww BLK WAT 7 BLK WAT AK RC5 7 gt RC5 5 gt RC5 1D gt RC5 4 gt RC5 9 gt PC1 CONTROL BOARD RC1 PLG1 RC2 PLG2 RC3 PLG3 RC4 PLG4 RC5 PLGS RC6 PLG6 RC7 PLG7 RC8 PLG8 RC9 PL

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