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Miller Electric XR W User's Manual

1. TME 42 O 39 O JE O 4 1 40 O 410 F4 0 60 470 35 0 420 430 670 A H L A 2T EI FS 2 156 399 C Feeder Ire For W ircuit Diagram Figure 7 1 C OM 1581 Page 39 PULL GU MOTOR ASSEM 0 B2 s Q TRIGGER Q Q K ma NA V PLG1 On R4 2 PB1 A V NG Q 2 E KS Q X S d amp S SS ow V V V V V V NV Y B C A D G E F H d P NG Ly Y Y CORD 1 CORD 2 195 712 B 4 WARNING e Do not touch live electrical parts et e Disconnect input power or stop SN engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit OM 1581 Page 40 Figure 7 2 Circuit Diagram For Gun Notes OM 1581 Page 41 SECTION 8 PARTS LIST Hardware is common and not available unless listed gt This main assembly drawing shows the XR W water cooled model Some parts for the XR A air cooled model vary in appearance When differences occur they are called out in the part desc
2. 1 UO Tao ee A 113169 Gear Driver suu a rae run OR A e ce a ca 1 RL ID ve s 604 612 Screw Set Stl Sch 8 32 X 125 Cup Point 2 GF Hardware is common and not available unless listed Includes Items 15 19 114 188 F Figure 8 2 Motor amp Wire Drive 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 1581 Page 45 x Hardware is common and not available unless listed See Fig 8 1 Item 59 AN l e o 145 127 B Figure 8 3 Panel Front w Components Water Cooled Model Illustrated OM 1581 Page 46 Item Dia Par No Mkgs No Description Quantity Figure 8 3 Panel Front w Components Fig 8 1 Item 59 ur E NN AR 111 569 Meter Flow 6 60 1 ADO a Yn 111 633 Guard Flow Meter 1 Pei HO pui dol a Leste YAI 134 834 Hose Sae 187 Id X 410 Od Order By Ft 4ft CORDE FEL IS 056 851 Fitting Hose Brs Barbed Nipple 3 16Tbg 2 EE 010 606 Fitting Hose Brs Nut G2p218 2 ga E WIE d 056 108 Fitting Hose Brs Ferrule 425 Id X 718 Lg 2 EE 045 852 Clip Component 687Dia Mtg Adh Back
3. 1 Voltage Wire Speed Meter Optional 2 Voltage Wire Speed Switch Optional 3 Run In Speed Control Jog Switch Burnback Time Control Optional 6 Spot Continuous Switch Optional 7 Remote Voltage Control Optional 8 Power Switch 9 Time Range Switch Optional 10 Spot Time Control Optional 11 Flowmeter Optional 151 780 A 5 2 Safety Equipment Lj EA Na Wear the following while welding 1 Dry Insulating Gloves 2 Safety Glasses With Side Shields 3 Welding Helmet With Correct Shade Of Filter See ANSI Z49 1 Sb3 1 1 94 5 3 Work And Voltage Sensing Cable Clamps Tools Needed ES Lm y 1 Work Clamp Connect work clamp to a clean paint free location on workpiece as close to weld area as possible Use wire brush or sandpaper to clean metal at weld joint area 2 Voltage Sensing Cable Clamp Connect voltage sensing cable clamp to workpiece for constant current CC operations see Section 4 10 Sb4 1 2 93 Ref 144 451 A OM 1581 Page 24 5 4 Run In Speed Control 1 Run In Speed Control Use control to set wire feed speed before arc initiation After arc initiation wire feed speed is controlled by the Wire Speed Control on the welding gun see Section 5 12 The scale around the control is per cent of full range not wire speed As a general rule set run in s
4. 5 2 1 Sy Mboles UTNISEST ee late it oath sited nU NC MOLES nr ce er he des aU 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2 5 Principales normes de s curit 8 2 6 Information EMF seinen EA pel ete EN dt ye au ke en dA EE ea RE EE e 8 SECTION 3 SPECIFICATIONS ev IRR FE ELE Ae NEEN KR RE NKE E Rr RR nie 9 3 1 Wire Feeder Specifications 9 3 2 Gun Specifications 25 sos ep EUR ERE nOD RR x D aa A QUE CHER RIEN VO AU EARS 9 3 3 Duty Cycle And Overheating ennen enken keen ennnt 9 SECTION 4 INSTALLATION y ti 51 23 AA o 10 4 1 Connections With A CC CV Or CC CV Voltage Welding Power Source Having A 14 Socket Receptacle 4 2 Connections With A CV Welding Power Source Having Separate 115 VAC And Contactor Control Re Lee Le 11 4 3 Connections With A CC Welding Power Source Having A Contactor Control Receptacle 11 4 4 Connections With A CC Welding Power Source And A 115 VAC 12 VDC Secondary Contactor 12 4 5 Removing Top Cover Of Pistol Grip Gun 12 4 6 Air
5. 1 8 RECESS 209 031 209 047 Ref 803 909 A 803 932 803 933 803 934 Figure 9 1 Consumables Flowchart For XR A And XR W Pistol Guns OM 1581 Page 52 Item Part No No Description Quantity Figure 9 1 Consumables Flowchart Table 9 1 Nozzles mp 176238 Nozzle Spot Flat Requires Diffuser 209099 Used With Any Heavy Duty FasTip Contact Tip 1 e N gare due 176240 Nozzle Spot Inside Corner Requires Diffuser 209099 Used With Any Heavy Duty FasTip Contact Tip 1 a spa 176242 Nozzle Spot Outside Corner Requires Diffuser 209099 Used With Any Heavy Duty FasTip Contact Tip 1 lan 199 610 Nozzle Screw On Brass 1 2 In Orifice 1 xcd umts 199611 Nozzle Screw On Brass 3 4 In Orifice Straight 1 ME 199612 Nozzle Screw On Brass 3 4 In Orifice Straight Heavy Duty 1 lee en 199 613 Nozzle Screw On Brass 5 8 In Orifice 1 ed res 199614 Nozzle Screw On Brass 5 8 In Orifice Heavy Duty 1 D TT 199615 Nozzle Screw On Copper 1 2 In Orifice 1 EM 199616 Nozzle Screw On Copper 3 4 In Orifice 1 2 viret 199617 Nozzle
6. 1 14 R45 46 028 770 Potentiometer C Sltd Sft 1 T 2W 1 Meg Ohm 2 Ho E S6 011 770 Switch Tgl Spdt 5A 125V 1 naat TO os S5 04011 609 Switch Tgl Spdt 15A 125VAC 1 17 R50 035 897 Potentiometer C Sltd Sft 1 T 2W 1000 Ohm 1 18 PC4 RC20 139 508 Circuit Card Filter saute dates a nens 1 T PLG14 115092 Housing Plug amp Sockets 1 Mm EPIIT 44097922 Knob Pointer 2 MON arse S 44940097 922 Knob Pointer 1 vea d s oss ST afin 111 997 Switch Rocker Spst 10A 250VAC 1 EL id 057 357 Bushing Snap in Nyl 937 Id X 1 125Mtg Hole Water cooled Model 1 B Rp AE 070 371 Blank Snap in Nyl 1 093 1 125Mtg Hole Air cooled Model 1 E ee mieu Eis 030170 Bushing Snap in Nyl 750 Id X 1 000Mtg Hole 1 Part of Gas Flow Meter Option Part of Meter Kit Option Part of Spot Weld Control Option Part of Voltage Control 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
7. 1 M RES 136 679 Clamp Strain Relief 1 man PG ER 132269 Screw Mach Stl Rdhph 8 32 X 375 1 ADO unice 214743 Case Gun Lh Rh Molded Halves 1 BT masala handa BIS ENEE NADAAN A REM UE BAONG eR rd ERA 32 eer nni Deleted Leia bte AEN e AARTEN AEN PASS DRE E ARA EE Em Deleted iioii aS ePi AA dad DERE A ieee nad aie eee MER 94 B2 230947 Motor Gear Pm 24 VDC 420 RPM 10 2 1 Ratio W Conn 1 H ar ERR nng 602 066 Screw Mach Stl Trh 6 32 X 250 2 i290 eed ase aoe 164 592 22 TNGYER ENEE 1 e RR EIE 058 262 CAP ET EE 1 38 Fig 8 5 231531 Head Tube Assy Air Cooled 1 38 Fig 8 5 231532 Head Tube Assy Water Cooled 1 SC CR etus 164 582 Housing Wire Drive 15A amp 30A Models Includes Items 24 amp 37 1 TIC 164 581 Housing Wire Drive 15W amp 30W Models Includes Items 24 amp 37 1 tas 151 661 Screw Set 10 32 X 125 Cup Sch 30W Models Only 2 340 sobole 133365 Clamp Head Tube 1 EX Caco 000 417 Screw Cap Stl Sch 10 24 X 1 000 2 42 aa 203 758 Cable Power 15A Model Consisting Of
8. 1 Sie AN 4054202 2 40351m 09 A ON 1 M2 pores 054201 045in 1 2mm eh 1 Im 199 593 3 64 in 1 2 mm Aluminum Wire 1 ME IPS 044 006 aT 1A e fim ice er het dt Mete AG gebe sce mita 1 cd o MAE 047 566 1 16 in 1 6 mm 1 iE res 202933 1 16 in 1 6 mm Aluminum Wire 1 Table 9 6 Gas Diffusers naa AWA 198 857 1 8 in Tip Recess For Extra Heavy Duty FasTip Contact Tips 1 D iid vis aS tuns 199623 Flush Tip For Extra Heavy Duty FasTip Contact Tips 1 E L E 199621 1 8 in Tip Recess For Value Multi turn Contact Tips 1 wile EE 199 622 Flush Tip For Value Multi turn Contact Tips 1 s arr ra 227 749 1 8 in Tip Recess For Heavy Duty FasTip Contact Tips Standard On All Guns 1 bieten 231511 1 4 in Tip Recess For Heavy Duty FasTip Contact Tips 1 mE EE 231512 Flush Tip For Heavy Duty FasTip Contact Tips 1 e ren 209 031 Slip On Recessed Diffuser Requires Nozzle 209033 Or 209034 And Insulator 209047 Used With Any Tapered FasTip Contact Tip 1 nG du 209 032 Slip On Flush Diffuser Reguires Nozzle 209033 Or 209034 And Insulator 209047 Used With Any Tapered FasTip Contact
9. OM 1581 Page 29 6 2 Changing Or Cleaning Gun Drive Roll Turn Off wire feeder and welding power source 1 Top Cover 2 Pressure Roll Assembly Cut off wire where it enters pressure roll assembly area 3 Setscrew 4 Current Pick Up Tab This tab helps prevent burnback caused by welding arcs inside the contact tip This tab may be re moved to provide an insulated drive roll If tab is removed a smaller di ameter contact tip is recom 1 mended See options in Parts List Lightly grease top of tab before rein stalling 5 Drive Roll Use wire brush to clean drive roll Install drive roll with desired groove down and turn drive roll so one setscrew faces flat side of shaft 6 Bearing 7 Liner Line up drive roll groove with bear ing groove and liner opening Tighten setscrews If changing drive roll in feeder proceed to Section 6 3 Thread welding wire through gun and adjust drive roll pressure if necessary see Section 4 15 Close and secure pressure roll assembly Reinstall top cover Tools Needed sen TB e ty Ref 151 599 F OM 1581 Page 30 6 3 Changing Feeder Drive Roll And Wire Inlet Guide AN
10. Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l Etat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation OM 1581 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 Safety 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 magn tiques et
11. 1 AQ naay magan 203 759 Cable Power 30A Model Consisting Of 1 na lt iM 1333627 Straf Reliet Cable IA e esee NAMAN PANIG KANG LI dr 1 44 R4 200 096 Potentiometer C Sitd Sft 1 T BW 10K Ohm 1 pe rs wand sns 144861 Washer Anti turn 1 AB os xxn 135 127 Lock Shaft Pot 250 32 X 125Dia Shaft 1 Eon de s eee n 602 169 Screw Set Stl Sch 8 32 X 187 1 AO di deis 134 856 Knob Speed Control 1 10 140 Shaft X 1 125 Od 1 sed s run Deleted DU KA ah ins aera tai ane cee 50 PB1 000369 Switch Lim 10A 125 250VAC Dpst Plgr 1 E she 183 884 Spring Cprsn 240 Od X 026 Wire X 1 000 1 D2 venus 184 101 Washer Shldr 140 Id X 250 Od 1 o lt cba Sr ela 217 934 Screw K40x 20 Pan Hd trx Stl Pld Pt Thread Forming 4 ME ep 162042 Contact Current Pick Up 1 ADD as sar nad 602 198 Washer Lock 141 Id Stl Split 4 256 EA 134 624 Bearing Flg Nyl 140 Id X 187 Od X 375Flg X 031Thk 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Part
12. Wire feeds shielding gas flows but welding wire is not energized Clean or replace drive rolls See Troubleshooting section in welding power source Owner s Manual see Sections 6 2 and 6 3 Wire feeds erratically Check and correct drive roll pressure see Section 4 14 Clean drive roll or replace drive roll see Sections 6 2 and 6 3 Gun overheating water cooled models Be sure coolant flowrate is at least 1 qt min 0 95 L min Corrosion buildup in gun decreasing coolant flowrate Backflush coolant system clean coolant system filter and clean fittings see Section 4 16 OM 1581 Page 38 SECTION 7 ELECTRICAL DIAGRAMS PLGS n RE KIT Ng i si 37 lt RCI 2 RC5 1 gt GRN lt KAY 2N RC5 2 gt gt 32 RC5 3 gt gt HIM RCM WAT dt 13 oo 2 AK lt RC1 3 gt gt G 6 B EBENE PLG52 7 2 lt 3 PLG51 PLG50 tm a lt lt S 7 RES 2 RED pe RCI 4 gt gt K5 c gt o lt a lt I lt 2 lt oz lt lt RC3 8 H ax 38 RC3 5 gt gt lt lt 2 E gt AD lt lt I lt o lt lt RC3 7 INCH We 15V CLOSUI s2 gt gt CONNECT PLG50 PLG51 a of RC3 3 n 3 RUN IN m SPEED CONTACT CLOSURE Power 5 CONNECT PLG50 PLG52 VA E eS Ka si RC3 10 gt gt 7 3 PD gt 44_ Buc 70 Bm MOTOR B H gt SS GUN BRAKE Ax CONTROL RC3 2 4 4 AN ASSEMBLY lt lt AI Le TC l BOARD gt gt lt
13. OM 1581 137 532Y 2007 01 m Miller MIG GMAW Welding Description Wire Feeder And Feeder Gun XR A And XR W OWNER S MANUAL File MIG GMAW ES Visit our website at www MillerWelds com 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 n U E Bl E PEENI 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 Working as hard as you do s every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And if for some reason the
14. Ref 803 348 G OM 1581 Page 33 6 8 Replacing The Liner Fan GO Split End A Turn Off welding power source and wire feeder 1 Drive Roll 2 Collet Nut Lay gun cable out straight Remove drive roll on gun and collet nut on on both ends of liner tube assembly and remove old liner 3 New Liner Insert split end of new liner into liner tube assembly and continue feed ing liner through cable assembly until liner is through liner tube as sembly and all of split portion is vis ible EF If gun is a 15 ft 4 5 m model push the split end of liner through until the opposite end is sticking out of the gun con nector 1 to 2 inches 2 5 to 5 cm After trimming the section with the split on it can be saved to use as another replacement liner Cut off split portion of liner Replace front collet nut with new plastic nut from the liner kit Reinstall steel nut at gun connector and tighten onto liner F May be easier to replace the collet nut with the liner conduit removed from the gun housing block The liner end will not stick out of the plastic collet nut supplied with the liner kit At the gun connection end cut liner as close as possible to control push motor drive rolls Refer to Owner s Manual for in structions on rethreading wire Ref 802 536 E 151 599 F 200 371 OM 1581 Page 34 6 9 Replacing Hub Assembly Turn Off wire fee
15. Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 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 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 1581 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 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 Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and spa
16. Use switch to select either an un timed continuous weld cycle or a timed spot weld cycle Both weld cycles consist of the following steps run in weld untimed or spot time and burnback 2 Time Range Switch Use switch to select spot weld time range 3 Spot Time Control Use control to set spot weld time Welding wire feeds at speed se lected on the gun Wire Speed Con trol Spot time starts at arc initiation The scale around the control is marked in seconds A Burnback Time Control Use control to adjust time up to 0 25 seconds that the welding wire is electrically energized after the wire stops feeding If welding wire sticks in the weld puddle increase burnback time If wire burns back into the gun contact tip decrease burnback time The scale around the control is marked in fractions of a second 5 8 Remote Voltage Control Optional 1 Voltage Control Use control to adjust arc voltage at the wire feeder The scale around the control is marked in percent 5 9 Power Switch 1 Power Switch Use switch to turn unit On and Off OM 1581 Page 26 5 10 Flowmeter Optional CAUTION 9 Be sure that regulator flowmeter has preset conditions of no more than 50 psi 345 kPa gas pressure Wire feeding system is designed for maximum of 50 psi 345 kPa gas pressure 1 Flowmeter 2 Va
17. 1 F RE a haban 137473 Hose Gas In 15A 4 W Models Consisting Of 1 ma cee edna aani 137472 Hose Gas In 30A 4 W Models Consisting Of 1 DERE 056 851 Fitting Hose Brs Barbed Nipple 3 16Tbg 1 Kha Usate ient aiU 010 607 Fitting Hose Brs Nut 625 18 Lh Water Hose 1 Paca N Kd AA 010 606 Fitting Hose Brs Nut 625 18Rh Gas Hose 1 Vue RE ER RUP NG 056 108 Fitting Hose Brs Ferrule 425 Id X 718 Lg 1 a dba ER dud 134 834 Hose Sae 187 Id X 410 Od 15A amp W Models Order By Ft 16ft Pratt AA 134 834 Hose Sae 187 Id X 410 Od 30A 4 W Models Order By Ft 31ft VENUS eise E LS e deis 089 120 Clamp Hose 375 450Clp Dia Slfttng 1 J E 000 571 Hose Water Xr 15 4 30W Models Consisting Of 2 EENEG 056 851 Fitting Hose Brs Barbed Nipple 3 16Tbg 2 Ee 010607 Fitting Hose Brs Nut 625 18 Lh 2 EE 056 108 Fitting Hose Brs Ferrule 425 Id X 718 Lg 2 cua uh Ta taut 134 834 Hose Sae 187 Id X 410 Od Order By Ft 10f ex oM ea da 048 837 Hose Gas Consisting Of 1 D eee E acis RUN kma aya 010603 Fitting Hose B
18. OM 1581 Page 47 F Hardware is common and not available unless listed co m 38 Fig 8 5 Includes Items 24 amp 37 e LO 803 706 C Figure 8 4 Exploded View Of Gun OM 1581 Page 48 Item Dia Part No Mkgs No Description Quantity Figure 8 4 Exploded View Of Gun D 214 145 7 COVER voce een a fu a QUO ERTIQH I eds DUNT RIP 1 ie bon quadrare Deleted iii dex Eee tere EE AA EE 194 405 Conduit W Fitting 15ft 15a W Models 1 AA E 204 422 Conduit W Fitting Molded 15 Ft 1 TIME 220879 Tubing Nyl 120 Id X 175 180 Od Xroll 16ft pO Da BC d PNE data 216001 Nut Liner Collet Retaining 1 TN Ba NN aala 185106 Nut Liner Collet II e i hem ss 1 Lh ger vs NG agn 194 410 Conduit W Fitting 30ft 30a W Models 1 RTE a BAG Ka 204 425 Conduit W Fitting Molded 30 Ft 1 MAN Mat RM Na 220 879 Tubing Nyl 120 Id X 175 180 Od Xroll 32ft DEG er Y pai 216004 Nut Liner Collet Retaining 1 O GANG 185 106 z s Nut Einer Collet asia oa n vaut 1 nM 137 474 Hose Water In 15W Model Consisting Of 1 M MEUM 137 475 Hose Water In 30W Model Consisting Of
19. lectriques Le courant de soudage pendant son passage dans les c bles de souda ge 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 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 L accumulation 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 1581 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 telephone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 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 Sta
20. lt 6 gt EN G CW MHT 69 Ges Sex S S ee PUSH MOTOR OPTIONAL ge RED OTHER AK 34 NCH ka 7 Sv 3 GAN aZ 030 035 lt lt p gt d lt lt RC3 6 EL 1 A gt SEM 00 c RCI 7 RC20 e N Le ke T 47 1 1 1 i o NG A A PLG2 LONG SPOT I SHORT CONT 67 oA 3 sY gt gt gt gt a 5 FLOW SWITCH OPTIONAL WATER A 8 C D CODLED MODELS ONLY 22 27 5 155 160 F METER AND SPOT TMER Y V V Va OPTIONS ARE USED CONNECT A PLG13 PC2 TO Roe PCT amp SENSE ACA AR GONNECT PLG2 PCT TO RCE Je shes LEAD BA BG B BH BC 44 145146 47 e gt H Al e un BF S M ATATATA A D ON RC7 p H Y T popa gt 57 AB i cw ee E AA AD ON RCB d 2 BBB 42 iui ES BA BH ON RCO c Q E E ces gt 6 SPOT TIME CA CF ON RCD ADD 3 C13 N PLG12 i PC2 FCS A Ee RC15 6 DIGITAL METER 32 POT BURNBACK B A RC15 4 OPTIONAL RC16 5 gt gt 0 OPTIONAL me DE E FROM T1 ES Ac o S ROBI a WARNING e Do not touch live electrical parts CB GA ce og e O E RC15 8 h V V V V PLGII 5N e Disconnect input power or stop 5 R Kap F METER OPTION IS NOT USED engine before servicing E CONNECT PLGfl PC3 TO RC2 PCI Do not operate with covers removed 38 39 F SPOT TMER OPTION IS NOT USED ELECTRIC Have only qualified persons install R46 CONNECT PLG2 PCT TO PLGI2 A PC2 SHOCKHAZARD use or service this unit cw BURNBACK
21. 1 T AA cara tessa 089 120 Clamp Hose 375 450Clp Dia 2 sr Det eed 112 090 Fitting Pipe Brs Elb 1 8Npt X 3 16 Hose 2 2k Of Earl ae fue 097 922 Knob Poimter 0 0 0 ccc eee eee teen eee 1 ple EE EE Nameplate Order By Model And Serial Number 1 UD ECKER 139 678 Fitting Water Water cooled Model 1 eO vdd e x aea ex ex 000 527 Blank Snap in Nyl 875Mtg Hole Air cooled Model 1 oi WEE 000 434 Fitting Gas cette ETE 1 vec UA EA a 115 443 Stand off No 6 32 X 750 Lg 2 salaan Ge 2 139 897 Circuit Card Meter 1 PR PLG12 115 090 Housing Plug amp Pins 1 stars PLG13 e6115 094 Housing Receptacle 4 Sockets 1 ET PLG15 e6115 092 Housing Plug amp Sockets WA RE Pawa PLG16 e6131 055 Housing Receptacle amp Sockets 1 Seiad KUNA EE 136339 Cover Opening Meter UE 120 304 Blank Snap in Nyl 250Mtg Hole 1 Doe dee RAM sov 073 562 Potentiometer C Sitd Sft 1 T 2W 10K Ohm 1 mga CE S2 were 120 400 Switch Tgl 3Pdt Mc 15A 125VAC
22. 8 32 X 125 Cup Point 2 ELM 114 045 Screw 6 32 X 500 Hexwhd Slt Stl Slffmg 3 se DY anstatt caries codd 134 623 Bearing Idler Roll 1 su O ox bua ak eee 132852 2 Arm Pressure Praia nexu aei idc ade tee EY An dieu 1 PATATE NET sts 605 798 Washer Shldr Nyl 375 Od X 168 Id X 080 2 sk dO dae aree E 133 083 Spring Tension Adj Drive Roll 1 ies d Muss ata s dus 144 860 Screw Mach Stl Flh 8 32 X 437 1 BR o e cote hug 058 968 Ring Retainer Esne eee eU E des maitre etat team Rte id 1 A A Er du 1935474 e PUD s Te L iet om Mare eg sacked Bb Bagana its Gt 1 EENEG 155050 Screw Thi mb uiui lese erp mag ara eR E PP een 1 EE gd 134 799 O Ring 176 Id X 070 Cs Used W Thumbscrew 1 v BO atta VA 135 126 Screw Set Stl Sch 6 32 X 125 Cup Point 1 24 Lusso 135 580 Fitting Gas sue A dae 1 OM 1581 Page 49 Item Dia Par No Mkgs No Description Quantity Figure 8 4 Exploded View Of Gun Continued sige 20 xiv bens 112 896 Spring Cprsn 240 Od X 020 Wire X 437 1 S2 2D xit tits 135 773 Knob Thumb Tension Adjusting 8 32 1 xe ih Gata ute don 143 360 Screw Mach Stl Rdh 8 32 X 500
23. Arm Pressure Roll 25 5 eese EH ANA exce ve d ve 1 PUN REN PE el 058 409 200500 JB ANING iio reser EE 1 sb quada us 112 887 Pin Hinge c ilg DD eR RAE EUER AUR piel 1 TE NUT 057 544 Spring Cprsn 240 Od X 026 Wire X 1 000 1 er Mao Ab An IMEE 120 397 Nut Thumb Tension Adjustment 2 cee eee eee eee 1 om 147 626 Cover Gear Wire Drive 1 aie b man 058 549 Guide Wire Inlet 1 16 1 L rasta ent ae 602 306 Pin Spring Cs 125 X 500 2 SEAS weet ees 008 667 Bearing Ball Rdl Dbl Row 250 X 687 X 31 2 sa EE 113170 Gear amp Shaft MOTO ic sre da EAR Gees 1 AUD secre 147 624 Case Gear Wire Drive 1 SON NEE 147 625 Block Anchor Conduit 1 td af eine anse 054 263 Screw Thumb Stl 250 20 X 500 1 scl B rte 120 398 Roll Drive V Groove 030 1 16 Wire Consisting Of 1 ie KS e rm pais 602 169 Screw Set Stl Sch 8 32 X 187 Cup Point 2 Je ser nr 605 971 Washer Shldr Nyl 236 Od X 195 Id X 042Thk 3 ntes onda BARYO 113162 Insulator Motor 1 veda BT sva 113898 Motor Torque 115VAC
24. Feeder With Gun 115 Volts AC 3 Amperes At 50 60 Or 100 Hz Power 30 Volts DC 70 875 ipm 1 9 22 2 mpm Length 19 in 483 mm Width 9 1 4 in 235 mm Height 15 1 4 in 387 mm 12 in 305 mm Air Cooled A Models Or Water Cooled W Models Models With 15 ft 4 6 m Cable Assembly Net 56 Ib 25 kg Ship 58 Ib 26 kg Models With 30 ft 9 1 m Cable Assembly Net 63 Ib 29 kg Ship 65 Ib 30 kg 3 2 Gun Specifications Specification Description Input Voltage Duty Cycle Air Cooled Models Duty Cycle Water Cooled Models Wire Size Range 30 Volts DC At 200 Amperes 10096 Using Argon Or Argon Mixture Shielding Gas At 250 Amperes 6096 Using Argon Or Argon Mixture Shielding Gas See Section 3 3 At 400 Amperes 10096 Using Argon Or Argon Mixture Shielding Gas See Sec tion 3 3 030 Thru 1 16 in 0 8 Thru 1 6 mm Aluminum Wire 030 Thru 045 in 0 8 Thru 1 1 mm Hard Or Cored Wire 3 3 Duty Cycle And Overheating O Continuous Welding Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty Air Cooled Models 100 Duty Cycle At 200 Amperes Using Argon 60 Duty Cycle At 250 Amperes Using Argon 0 06 6 Minutes Welding 4 Minutes Resting Water Cooled Models 100 Duty Cycle At 400 Amperes Using Argon R Continuous Welding OM 1581
25. Ha e Turn Off wire feeder and welding EX Ge power source If F1 opens the unit shuts down To check or change F1 proceed as follows 1 Fuse Holder Cover 2 Fuse F1 See Parts List For Rating O 9 Push And Turn KO Pull Out And Replace F1 fo Push And Turn Insert new fuse into cover and in stall fuse with cover by pressing and turning cover clockwise 3 Circuit Breaker CB1 If CB1 opens the gun drive motor and contactor will not operate but gas flows when trigger is pulled The gun drive motor operates in the Jog mode with CB1 open Check for blocked gun liner Check for jammed wire binding drive gear or misaligned drive rolls in feeder Correct problem Allow cooling period and manually reset breaker Close and latch door Ref 151 779 A Ref 800 185 A 6 12 Water Flow Switch Optional For Water Cooled Models The water flow switch protects the gun from overheating If coolant flow rate drops below 1 qt min the water flow Switch opens and stops the welding wire from feeding See Section 6 13 for remedies to this trouble OM 1581 Page 36 6 13 Troubleshooting R jm A Wire Feeder Trouble Trouble Remedy Pressing gun trigger does not energize feeder Welding wire is not energized Shielding
26. In Feeder Route one end of weld cable through grommet through reed relay and connect to block in feeder using hardware shown Connect remaining end of cable to positive weld output terminal on welding power source Close and latch door Tools Needed IZ 5 8 1 1 8 in Ref 152 431 A OM 1581 Page 16 4 10 Voltage Sensing Lead Connections J Unit is factory set for constant volt age CV welding To set unit for Se constant current CC welding proceed as follows 1 Terminal Strip 2T 2 Strain Relief Loosen screws of strain relief NN L 3 Voltage Sensing Lead Route ring terminal end of lead through strain relief and connect ring terminal to terminal A of terminal strip 2T Tighten screws on strain relief 4 Motor Speed Control Board PC1 5 Jumper Plug 6 Receptacle RC5 For constant voltage CV welding place jumper plug in INT position Do not connect voltage sensing lead clamp to workpiece For constant current CC welding place plug in EXT position Connect clamp end of voltage sensing lead to workpiece Reinstall right side panel L IL DN Sdt Tools Needed EA O 1 4 in Ref 151 772 B OM 1581 Page 17 4 11 115 VAC Contactor Control Plug Information 1 Interconnecting Cord 2 115 VAC Contactor Control Plug PLG5 If CC or CC CV welding power s
27. Includes 1 usi TOi maman 220209 Jacket Outer Insulating 1 MA WA KAN TENA 220 216 Washer Flat 594idx1 3750dx 125t Black Vulc Fbr 1 en das eds 220 210 Head Tube Water Pistol Brazed 1 a AA oe 180 966 O ring 926 Id X 070 Cs 70 Duro Quadring 4 La NN Eds INO 212 156 Liner Phos Bronze 030 1 16 Wire X 7 313 1 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 1581 Page 51 SECTION 9 PARTS LIST INCLUDING CONSUMABLES 030 1 16 WIRE G ei i HEAVY DUTY FASTIP CONTACT TIPS CD VALUE MULTI TURN FASTIP CONTACT TIPS 030 1 16 WIRE EXTRA HEAVY DUTY FASTIP CONTACT TIPS 035 1 16 WIRE Item Number 1 SPOT NOZZLES RAT 176 238 INSIDE CORNER 176 240 OUTSIDE CORNER 176 242 SCREW ON NOZZLES COPPER 5 8 ORIFICE rel 15 16 0 0 Hol 7 4207 313 HEAVY DUTY 5 8 ORIFICE BRASS 199 614 OR oH COPPER 199 618 CH HEAVY DUTY 3 4 ORIFICE geg BRASS 199 612 OR m COPPER 199 617 STANDARD 1 2 ORIFICE g
28. MARC et 046 432 Holder Fuse Mintr 250 X 1 250 Panel Mtg 1 UE sas SA suus 011 232 Switch Pb Spdt isses a xa Ee x Ger oe URS 1 78 CB1 174 092 Circuit Breaker Man Reset 1P 7A 250VAC 1 miso PONG 20s MM 038 861 Block Term 20A 3P 1 EE 601 219 Link Jumper Term BIK 20A d WEE 211 989 Fitting W Screen nen enn n kk nn nn n nerne 1 When ordering a component originally displaying a precautionary label the label should also be ordered Part of Spot Weld Control Option Part of Voltage Control Option Part of Water Flow Shutdown Switch Option Recommended Spare Parts 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 1581 Page 44 Item Dia Part No Mkgs No Description Quantity Figure 8 2 Motor amp Wire Drive Fig 8 1 Item 71 A ARR DE 115 191 Drive Assembly Wire Consisting Of 1 NC EE 058 968 Ring RetainerE 1 H DECH 605 798 Washer Shldr Nyl 375 Od X 168 Id X 080Thk 4 iod hens sente 120395 Spring Tension Pressure Roll 1 ln De qr E NL ee 112713
29. 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 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 implie
30. Page 9 SECTION 4 INSTALLATION N OTE Ee Be sure that contact tip liner and drive rolls are correct for wire size and type See Section 5 to change parts as needed See Section 7 for list of other available contact tips Review Section 4 1 through Section 4 4 to determine how equipment will be connected Air cooled models are shown in Section 4 1 through Section 4 4 For water cooled models supplied water hoses must be connected from wire feed er to coolant supply Read entire Section 4 before installing equipment 4 1 Connections With A CC CV Or CC CV Voltage Welding Power Source Having A 14 Socket Receptacle 1 Constant Current CC Constant Voltage CV Or Constant Current Constant Voltage CC CV Welding Power Source 2 115 VAC Contactor Control 14 Pin Plug 3 Workpiece 4 Voltage Sensing Lead Connect lead to workpiece for CC welding only 5 Gun 6 Wire Feeder 7 115 VAC Contactor Control Cord 8 Gas Cylinder 151 774 F OM 1581 Page 10 4 2 Connections With CV Welding Power Source Having Separate 115 VAC And Contactor Control Receptacles 1 Constant Voltage CV Weld ing Power Source 2 Plug Obtain matching plugs for connect ing to power source receptacles 3 Workpiece 4 Voltage Sensing Lead Do not connect to workpiece 5 Gun 6 Wire Feeder 7 115 VAC Contactor Control Cord 8 Gas Cylinder 151
31. Pressure Roll Assembly Lift arm and open pressure roll assembly 2 Wire Conduit Lay wire conduit out straight 3 Jog Switch Push Jog switch up to feed wire through wire conduit 4 Drive Roll For wire sizes 035 in 0 9 mm and smaller use small groove and 047 in 1 2 mm and 1 16 in 1 6 mm use large groove 5 Contact Tip Manually thread wire along drive roll groove and out contact tip 2 in 51 mm Close pressure roll assembly 6 Tension Thumbnut 7 Pressure Adjustment Knob 8 Final Pressure Adjustment Turn On feeder and check drive roll pressure by feeding wire against a piece of wood or concrete surface wire should feed steadily without slipping If necessary adjust pressure adjustment knob in gun Turn Off feeder and welding power source Reinstall gun cover Close and latch feeder door 151 599 F 151 666 E Ref 176 700 A Ref S 0651 4 16 Coolant Guidelines CAUTION gun feeder cooling passages Do not use antifreeze containing stop leak additives e Use of other coolant voids warranty INCORRECT COOLANT OR COOLANT CONTAINING STOP LEAK ADDITIVES can corrode and or plug Use only a mix of 50 distilled water and 50 high quality automotive antifreeze as proper coolant for this product N 50 50 Distilled Water amp Antifreez y Draining Filling Tighten Connections Follow these guidelines to decrease corrosion in gun feeder an
32. 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 away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder 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 A k FIRE OR EXPLOSION
33. Welding Power Source Flowmeter IZ 5 8 1 1 8 in Ref 151 771 A OM 1581 Page 15 4 9 Water Cooled Feeder Connections Connect To Return Fitting On Coolant Supply Rear Panel m f O 8 7 10 Connect To Positive Weld Output Terminal On Welding Power Source Connect To Supply Fitting On Coolant Supply Connect To Regulator Flowmeter Obtain coolant supply 1 Gas Hose Grommet 2 10ft 3 m Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet and connect hose to rear of Gas fitting in feeder Connect remaining end of hose to regulator flowmeter 4 Coolant Supply Hose Grommet 5 10 ft 3 m Water Supply Hose With 5 8 in Adapter Fitting 6 Rear Of Water Fitting Left Hand Threads Remove 5 8 in adapter fitting from hose Route one end of a water hose through grommet and con nect to rear of Water To Gun fitting in feeder Connect remaining end to supply fitting on coolant supply 7 Coolant Return Hose Grommet 10 ft 3 m Water Return Hose 9 Connection Block Left Hand Threads Route one end of remaining water hose through grommet and con nect to rear of connection block not shown Connect remaining end of hose to return fitting on coolant supply 10 Weld Cable Grommet 11 Weld Cable To Welding Power Source Select and prepare weld cable according to welding power source manual 12 Current Sensing Reed Relay 13 Weld Cable Screw
34. and install plug onto contactor control cord Obtain 115 VAC plug and connect to 115 VAC cord as follows green lead to ground white lead to 115 VAC common black lead to 115 VAC hot 6 Plug PLG50 7 Plug PLG51 8 Plug PLG52 Unit shipped with PLG50 con nected to PLG51 to provide 115 VAC for contactor If contact closure needed for con tactor connect PLG50 to PLG52 Tools Needed r EE 151 773 C OM 1581 Page 19 4 13 Installing Wire Spool Turn Off wire feeder and welding power source 1 Wire Spool 2 Top Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced open pressure roll assembly in gun and cut welding wire off at contact tip For welding power sources without tese eee uae M contactor retract wire onto spool Q For welding power sources with a T contactor energize power source turn On feeder press Brake Release button see Section 5 11 and retract wire onto spool Close gun pressure roll assembly and reinstall top cover 5 Hub 6 Hub Pin 7 Compression Spring Optional For 8 in Spool 8 Retaining Ring Slide spool onto hub so wire feeds off bottom Turn spool until hub pin fits hole in back of spool Reinstall retaining ring Thr
35. date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids 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 Bernard Branded Mig Guns No Labor Wel
36. de s curit indiqu es ci dessous ne constituent qu un e Ne pas 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 gans les normes de piii hand mer dans la Section 2 5 Lire et lt Ne pas enrouler les c bles autour du corps e USA Pa 3 g e Sila pi ce soud e doit tre mise la terre le faire directement avec un A Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine H n n x p sonnes notamment les enfants de l appareil Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e 1 UNE DECHARGE ELECTRIQUE peut e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le 9 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut bait err e Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures pa un rar ja t S SK mi SL s Ge nt Se i xn graves Le circuit de l lectrode et de la pi ce est dese el que tous GS PANNEA
37. eee Mle 605 970 Washer Shldr Nyl 310 Od X 252 Id X 064 Air cooled Model 3 DO it 2 Tes 090 465 Transformer Signal 115V 24Vct 4A 1 PEE pus rase 090 439 Label Warning Electric Shock Can Kill 1 0455 ouvert i sg 089 573 Plate Keeper Link Iock 2 ix DO uiscera 131 318 Insulator Block Connection Water cooled Model 1 DO cenis oe e EZA 113 166 Insulator Term Air cooled Model 1 LAE tos arra eei a 131 311 Block Connection 1 Na BB m 150 067 Fitting Water Block Extension 1 Ma EE Fig 8 3 Panel Front W Components 1 5 605 i cubes 121276 Bushing Strain Relief 709 Id X 1 115Mtg Hole 1 se s 134834 Hose Sae 187 Id X 410 Od Order By Ft 2ft 20624 Les res 089 120 Clamp Hose 375 450Clp Dia Slfttng 4 DC E S8 e66164 963 Switch Flow W Fittings 1 na EE 601966 Screw Cap Stl Hexhd 375 16 X 1 250 Water cooled Model 1 sed uo cr 117 498 Terminal Pwr Weld Air cooled Model 1 ash sistat 117 496 Washer Fbr 312 Id X 750 Od X 062Thk Air cooled Model 2 EE 075 150 Washe
38. transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B 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 Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 1581 Page 6 distance 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 de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et de
39. 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 the U S A to be registered to 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 Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Tal Symbol Usage stor qe ER ERA n e POUR nea UTE RE ea 1 122 Are Welding Hazards tette RA e d puce c ISSUE USE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings ennen enken enken teen eee eee 3 1 5 Principal Safety Standards 0 cece nett eee eens 4 1 6 EME Information i siente a O rm px ese Fuld ER OE alls net wy wena Saale x ee oe PE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION
40. 3 323503332303636 3n PB E Re ged A A ES MERERI nine 34 6 9 Replacing Hub Assembly WA AHS RE LI Karia n 35 6 10 Adjusting Aub Tension 1 ra EE A EA BER EK Aa 36 611 Ovetrload Protectior 2 tom cup AEN a oie E EN LIGNO GG ada wea ent glee 36 6 12 Water Flow Switch Optional For Water Cooled Models 36 6 13 Troubleshooting ve er re RR NEE b REX mine LA KG FEE EUR e Ed 37 SECTION 7 ELECTRICAL DIAGRAMS 0ooccccccccc nnn nnn n n nnn 39 SECTIONS PARTS LIS To tme rm EXER ERE NEERERRGR ATI RUM CE 42 SECTION 9 PARTS LIST INCLUDING CONSUMABLES 2222222202 044 n nnns 52 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks a special safety message EF Means Note not safety related 1 2 Arc Welding Hazards A A A pum 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
41. 775 G 4 3 Connections With A CC Welding Power Source Having A Contactor Control Receptacle 1 Constant Current CC Weld ing Power Source 2 5 Pin Or Two Prong Twistlock Plug Workpiece 3 4 Voltage Sensing Lead 5 Gun 6 7 Wire Feeder 3 Conductor Contactor Con trol Cord 8 3 Conductor 115 VAC Cord 9 Gas Cylinder 10 115 VAC Plug Obtain plug for wire feeder 151 776 F OM 1581 Page 11 4 4 Connections With A CC Welding Power Source And A 115 VAC 12 VDC Secondary Contactor 1 Constant Current CC Weld ing Power Source Workpiece Voltage Sensing Lead Gun Wire Feeder 3 Conductor 115 VAC Cord 3 Conductor Contactor Con S 10 RAD A D a trol Cord A 8 5 Pin Plug K 9 Secondary Contactor 10 Gas Cylinder 11 115 VAC Plug Obtain plug for wire feeder N DO a E N 151 777 F 4 5 Removing Top Cover Of Pistol Grip Gun 1 Top Cover Triangular Boss Push up on triangular boss to open door Door hinges on handle To open door fully push up on door until it clicks into position EF If door is pushed too far it will separate from handle If this happens the door can be rein stalled Push door back into original posi tion to close 802 528 C OM 1581 Page 12 4 6 Air Cooled Gun Connections 1 Gun Control Cable Insert plug into Gun Control recep tacle a
42. Cooled Gun Connections 13 4 7 Water Cooled Gun Connections 14 4 8 Air Cooled Feeder Connections 15 4 9 Water Cooled Feeder Connections 16 4 10 Voltage Sensing Lead Connections c cent eee 17 4 11 115 VAC Contactor Control Plug Information 18 4 12 Replacing 115 VAC Contactor Control Plug With Customer Supplied 5 Pin Or Twistlock Plug 19 4 13 Installing Wire Spool o eek e aer ME YS OR ee VU XR Y rv s 20 4 14 Threading Welding Wire Through Feeder 21 4 15 Threading Welding Wire Through Gun eee ken eee ker ennee 22 4 16 Coolant Guidelines s sA eee ananuna 22 4 17 Adjusting Wire Feed Starting Speed 23 TABLE OF CONTENTS SECTION 5 PERATION gE Weg TRAR A Wee YR e N 24 5 1 Front Panel Controls Of Feeder Air Cooled Model Shown 24 5 2 Safety Equipment uet RR ROW ERCOPHCUUPRETAG NE PEE ee RAO Y ARTIS Y 24 5 3 Work And Voltage Sensing Cable Clamps 24 5 4 Run In Speed Conittol uo AAA Nm PIE eRe KUHA 25 ee Ru EE 25 5 6 Voltage Wire Speed
43. ES 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 e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e Lutilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil 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 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 Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage
44. R t 1 NB a nan a 601 226 Insulator Vinyl Clamp Univ 25A erre 1 NE AE AA 600 848 Wire Lead Mot 12Ga Strd Order By Ft 35ft 2804 ead He eun ex 176 089 Tubing Plstc PVC Black 1ft USO eei 115 104 Connector Clamp Cable 500 1 a et 000 527 Blank Snap in Nyl 875Mtg Hole 1 D EEN 007 826 Cable Port No 18 3 C Order By Ft 11ft 34 PLG5 141162 Housing Plug amp Pins eee 1 85 rien nee 079 739 Clamp Cable Strain Relief 1 FOOT uL LEN 007 826 Cable Port No 18 3 C Order By Ft 11ft Mc 4007 826 Cable Port No 18 3 C Order By Ft 11ft M CAR 139 042 Bushing Strain Relief 270 480 Id X 804Mtg Hole 2 COT esrb eg 139 042 Bushing Strain Relief 270 480 Id X 804Mtg Hole 1 38 PC1 142 053 Circuit Card Motor Speed Control 1 EE PLG1 115 092 Housing Plug amp Sockets 1 m PLG2 115094 Housing Plug amp Sockets 1 ET PLGS 115 091 Housing Plug 4 Sockets 1 K Aidt PLG4 131054 Housing Receptacl
45. Re 057 357 Bushing Snap in Nyl 937 Id X 1 125Mtg Hole Water cooled Model 2 T Sen ees 057 357 Bushing Snap in Nyl 937 Id X 1 125Mtg Hole Air cooled Model 1 WANA WAA ate AA 070 371 Blank Snap in Nyl 1 093 1 125Mtg Hole Air cooled Model 1 B RS sucio REA 057 358 Bushing Snap in Nyl 1 000 Id X 1 375Mtg Hole 1 L Ke nas 134 201 Stand off PC Card 4 20 PC3 4114538 Circuit Card Spot burnback 1 ras PLG7 8 11 115 094 Housing Plug amp Sockets 3 T PLG9 115 092 Housing Plug 4 Sockets 1 norms PLG10 115 093 Housing Plug 4 Sockets 1 Se ANA ree 073 302 Bearing Ball Rdl Gol Row 669 X 1 378 X 39 2 AP o ad isse Bana 113 161 Block Bearing Front 1 NOB RA as 113165 Stand off 250 20 X 1 000 Lg 4 OA sl senses 120396 Shaft Spool 1 25 MP1 113 899 Brake W Terminals 1 2 26 sls 113 900 Block Bearing Rear 1 Dee Ver Mentes 601 228 Clamp Univ 25A cai dur one RUB re CREME racket iawn E
46. Screw On Copper 3 4 In Orifice Heavy Duty 1 Eb RS 198 855 Nozzle Screw On Copper 5 8 In Orifice 1 eid doces 199 618 Nozzle Screw On Copper 5 8 In Orifice Heavy Duty 1 SA ee 207 313 Nozzle Screw On Copper 5 8 In Orifice 15 16 OD 1 zu vet 209 033 Nozzle Slip On Copper 1 2 In Orifice Tapered Requires Diffuser 209031 Or 209032 And Insulator 209047 Used With Any Tapered FasTip Contact Tip 1 d doen boites 209 034 Nozzle Slip On Copper 3 8 In Orifice Tapered Requires Diffuser 209031 Or 209032 And Insulator 209047 Used With Any Tapered FasTip Contact Tip 1 Eu poc 209 035 Nozzle Screw On Copper 3 8 In Orifice Tapered Requires Diffuser 227 747 231 511 Or 231 512 Used With Any Tapered FasTip Contact Tip 1 s c 209 036 Nozzle Screw On Copper 1 2 In Orifice Tapered Requires Diffuser 227 747 231 511 Or 231 512 Used With Any Tapered FasTip Contact Tip 1 Table 9 2 Heavy Duty FasTip Contact Tips i 2r aate 206 185 030 in 0 8 mm 1 pO 206 186 035 in 0 9 mm 1 Agr dr at tae 206 187 040 in 1 0 mm or 035 in 0 9 mm Aluminum Wire 1 dT 206 188 045 in T TTT 1 AA 206 189 052 in 1 3 mm or 3 64 in 1 2 mm Aluminum Wire 1 e B der
47. Shielding Gas 1 Shielding Gas Oylinder 2 Valve 3 Gun Trigger Open valve on cylinder just before welding Gun trigger turns weld output and gas flows on and off see Section 5 12 Close valve on cylinder when finished welding 2 oy 1 sb5 1 6 92 S 0621 C Ref 151 666 E 1 Coolant Supply See Section 4 16 for coolant guidelines Turn On coolant supply before welding Turn Off coolant supply when finished welding Ref 150 755 A 5 15 Sequence Of Gas Metal Arc Welding GMAW Continuous Or Spot Install amp Put On Turn On Gas Turn On Feeder Connect Personal Safety Set Controls And Water If And Welding Begin Welding Equipment Equipment Applicable Power Source ssb6 1 9 92 OM 1581 Page 28 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance NAP z Turn Off all power before maintaining md 6 Months d 3 Months md 3 Months AN venu f D OV 559 Tape Or Replace A Replace See Unreadable Vy Cracked Section Labels gt Weld m Cable Clean gt And Replace y sa Tighten Cracked y Weld Parts 4 8 Terminals Rik 14 Pin Cord NY Gas Hose Gun Cable Blow Out Or Vacuum Inside During Heavy Service ee Clean Monthly 4 Gr Clean ay Drive JN Rolls 5 2 E
48. Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill bo 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 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 c
49. Switch And Meter Optional 25 5 7 Spot Controls Optional eee eee e eee eee 26 5 8 Remote Voltage Control Optional 26 5 93 HPOWOE SWIICD 1 339 83 a emisti Peu ta altes tute reta lie 26 5 10 Flowmeter Optional xR ka ek hd ae s 27 511 Internal Controls hae dec RA Kuga ABALA NAN Pee SE ee DRE TU E 27 5 12 QUA CONOS o KIA PN NG A O PE PS eee oats MG SEE RI C E 28 5213 Shielding G S 4 ove AAA RENT RN Ae EE ENEE A EE AUA EA 28 5 14 Coolant Supply For Water Cooled Models Only 28 5 15 Sequence Of Gas Metal Arc Welding GMAW Continuous Or Spot 28 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 29 6 1 Routine MaCast 29 6 2 Changing Or Cleaning Gun Drive Roll 30 6 3 Changing Feeder Drive Roll And Wire Inlet Guide 31 6 4 Replacing Or Cleaning Gun Drive Roll Bearing 32 6 5 Replacing Or Cleaning Feeder Drive Roll Bearing 32 6 6 Changing Gun Contact Tip ae tra eed qe n tr m tn et ees OE RU eS e Ne E RUE 33 6 7 Removing Diffuser In Air And Water Cooled Pistol Grip Guns 33 6 8 iReplacing The Linern
50. Tip 1 igo TR 209 099 Spot Diffuser Requires Spot Nozzle 176238 Or 176240 Or 176242 1 Table 9 7 Insulators esce us n du sti 232 284 Insulator Nozzle Collared Diffuser 1 nad sons suus 198 856 Insulator Rubber 2 20 cette ten eee a 1 AR ox lu EEN 209 047 Insulator Teflon Required When Using Diffuser 209031 Or 209032 With Nozzle 209033 Or 209034 1 Table 9 8 Barrel Assemblies Hs Di nue Kani 221 087 Barrel Assy Air Cooled Pistol 1 UD na 221 519 Barrel Assy Water Cooled Pistol 1 Table 9 9 Head Tube Assemblies Dedi Id Lt sedora ats 231523 Kit Head Tube Assy Air Cooled Pistol 1 LAS A Ree aig gant AUNA 231 524 Kit Head Tube Assy Water Cooled Pistol 1 OPTIONAL All contact tips are packaged in bags of 25 BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model is required when ordering parts from your local distributor OM 1581 Page 54 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 nee
51. To reduce magnetic fields in the workplace use the following procedures OM 1581 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 Offices 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 Boo 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
52. Tools Needed 5 16 in E Te E HA Turn Off wire feeder and welding power source Lay wire conduit out straight Open gun pressure roll assembly and cut welding wire off at contact tip 1 Pressure Roll Assembly 2 Wire Spool For welding power sources without contactor retract wire onto spool For welding power sources with a contactor energize power source turn On feeder press Brake Re lease button and retract wire onto spool 3 Shaft 4 Setscrew 5 Drive Roll Use wire brush to clean drive roll Install drive roll with desired groove in and turn drive roll so one setscrew faces flat side of shaft 6 Bearing 7 Wire Conduit Fitting Line up drive roll groove with bear ing groove and opening in conduit fitting Tighten setscrews 8 Wire Inlet Guide Pull guide toward rear of feeder to remove Install new guide Thread welding wire and adjust drive roll pressure if necessary see Section 4 14 Close and se cure pressure roll assembly Close and latch door Close gun pressure roll assembly and reinstall gun cover 151 778 Ref 151 781 B OM 1581 Page 31 6 4 Replacing Or Cleaning Gun Drive Roll Bearing Turn Off wire feeder and welding power source 1 Top Cover 2 Pressure Roll Assembly 3 Screw 4 Pressure Roll Remove as shown Use a wire brush to clean bearing Reinstall with washers and tighten Screw Close pressure roll assembly Reins
53. UX et couvercies sont correcementen sous tension lorsque le courant est d livr la place 3 ji sortie Le circuit d alimentation et les circuits internes de la machine 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 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 e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol 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 Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une sou
54. atoire 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 Nam An ee amp 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 bo tes antistati ques pour stocker d placer ou exp dier des cartes PC y E 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 re u l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geant le fil de soudage PAL DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels Ng que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettreles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE L
55. 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 quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e 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 pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation
56. azards 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 A 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 1581 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 cause severe burns Do not touch hot parts bare handed e 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
57. cidentel 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 LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester danger eX 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 homologu es Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t 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 Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le
58. d 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 C Miller Effective January 1 2007 Equipment with a serial number preface of LH 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 S 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 delivery
59. d cooling system 1 Coolant Mix distilled water and high quality automotive antifreeze Use anti freeze which does not contain stop leak additives Use of other coolant voids warranty N 2 Coolant System Tank 3 Changing Coolant Change coolant only if dirty Add coolant to keep level full 4 Tighten Connections 4 Keep gun connections tight s 0760 OM 1581 Page 22 4 17 Adjusting Wire Feed Starting Speed To adjust wire feed starting speed proceed as follows Turn Off wire feeder and welding power source Open right side panel 1 Motor Speed Control Board PC1 2 Motor Start Control Potentiometer R70 Turn potentiometer clockwise to increase time it takes the motor to ramp up to speed Remove protective white rubber cap before making adjustment Adjust potentiometer using a small nonconductive screwdriver Close side door Top Of PC1 D R6 Cs n 1 e e SECH y nr Tools Needed Nonconductive C ARO 1 4 in Ref 151 772 B Ref 142 054 B OM 1581 Page 23 SECTION 5 OPERATION US EZ ZS E SN 5 1 Front Panel Controls Of Feeder Air Cooled Model Shown 11 10 D Q d X o QO M NA A o
60. d warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation 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 2007 01 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 File a claim for loss or damage during shipment Contact the Delivering Carr
61. dcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s 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 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
62. der and welding X power source Remove gun top cover and open pressure roll assembly as shown in Section 6 4 Retract wire onto spool and remove spool Take hub apart as shown 1 Metal Brake Washer Flat Washer Brake Washer Hub Keyed Washer J Deo 20 my Spring Cap Screw DJ Oa Om BR Xd I H Retaining Ring Replace broken or worn parts and slide parts onto shaft as shown Adjust hub tension see Section 6 10 Thread welding wire see Section4 14 Close and latch door Close gun pressure roll assembly and reinstall gun cover Tools Needed CO 7h6in 151 778 B Ref 143 223 A OM 1581 Page 35 6 10 Adjusting Hub Tension Turn On welding power source and wire feeder to make this adjustment 1 Wire Speed Control Adjust control to wire speed for welding 2 Jog Switch Push up and then release Jog switch Hub tension is okay if wire unwinds freely but wire does not backlash when Jog switch is released 3 Cap Screw Turn cap screw to adjust hub ten sion Do not overtighten Turn Off welding power source and wire feeder Close and latch door Tools Needed IEC 7 16in 151 666 E Ref 802 536 Ref 176 700 A 6 11 Overload Protection
63. e amp Sockets 1 e ra PTE x3 038 783 Block Term 20A 12P 1 40 PLG50 131203 Housing Plug amp Pins 1 41 PLG51 52 131204 Housing Plug amp Sockets 2 42 C13 117 500 GCapacitO eene PUER tenn be We at M Age 1 43 SNI 110 079 Snubber Polye Mf SU 200VDC 1 AM EE 605 741 Clip Mtg Resistor 312 Id Core 2 45 R35 030 087 Resistor Ww Fxd 25W 200 Ohm 1 46 C9 114 215 Capacitor Polye Film 2 3Uf 250VAC 1 47 C14 044 602 Capacitor Polye Film 47Uf 400VDC 1 48 4T 038 785 Strip Terms icis cce rere Teva Ee the Do 1 E 134 201 Stand off Support PC Card 4 OM 1581 Page 43 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly Continued ux DO iie Rs Tf1 152 Skid Base csl EL ER RR ewe ete eae LANG 2 DAR 176 714 Cabinet Control licei hb ehh hana 1 RUE Ee 153 901 Label Caution The Recommended Coolant To Be 1 mp D2 Sean 605 970 Washer Shldr Nyl 310 Od X 252 Id X 064 Water cooled Model 4 la
64. e liners the strain relief will need to be removed from the control box Route cable through strain relief and connect to weld water from gun outlet on feeder Reinstall strain re lief Close and latch door Ref 802 536 E Ref 151 778 B 152 456 A OM 1581 Page 14 4 8 Air Cooled Feeder Connections 1 Gas Hose Grommet 2 10ft 3 m Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet and connect hose to rear of Gas fitting in feeder Connect remaining end of hose to regulator flowmeter 4 Weld Cable To Welding Power 5 Weld Cable Grommet 6 Current Sensing Reed Relay Source S Select and prepare weld cable ac O E cording to welding power source manual i EN P 7 Weld Cable Terminal In M i K J Feeder 3 Route one end of weld cable 3 through grommet through reed relay and connect to weld cable terminal in feeder Connect remaining end of cable to positive weld output terminal on welding power source 8 Gun Weld Cable Be sure that terminal of welding power source weld cable is in direct contact with terminal from gun weld cable Close and latch door Rear Panel Top View OQO 7 Connect To 5 Positive Weld Connect To Tools Needed Output Terminal On Regulator
65. ead welding wire see Section 4 14 Close and latch door or go on to Section 4 14 Tools Needed Ces IU Ref 151 771 A Ref 072 573 B Ref 151 599 F OM 1581 Page 20 4 14 Threading Welding Wire Through Feeder Tools Needed EF 1 Wire Spool Loosen wire from spool cut off bent wire and pull 6 in 150 mm of wire off spool 2 Tension Arm 3 Mounting Arm To open pressure roll assembly open tension arm and lift mounting arm 4 Wire Inlet Guide 5 Drive Roll 6 Wire Conduit Fitting Thread wire through wire inlet guide along drive roll groove and into fitting Close and secure pressure roll assembly 7 Tension Thumbnut 8 Jog Switch Turn On wire feeder For proper ad justment loosen thumbnut until drive roll slips when Jog switch is pushed up Grasp spool with one hand and turn thumbnut clockwise until motor stalls when Jog switch is pushed up Feed welding wire through gun see Section 4 15 Turn Off wire feeder Close and latch door 151 778 B Ref 176 700 A OM 1581 Page 21 4 15 Threading Welding Wire Through Gun 1
66. er 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 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 oxyg ne 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 curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de puiv risation La chaleur et les rayons de provinciales et locales l arc peuvent r ag
67. gas flows Secure plug from gun control cable into Gun Control receptacle on feeder see Section 4 6 Secure 115 VAC input plug connection see Section 4 11 Check fuse F1 see Section 6 11 Check water connection to feeder or gun see Sections 4 6 and 4 8 Check for kinks in water hose Be sure coolant supply is turned On see Section 5 14 Have nearest Factory Authorized Service Station Service Distributor check optional water flow switch if applicable see Section 6 12 Wire feeds shielding gas flows but welding wire is not energized Secure 115 VAC contactor control plug connection see Section 4 11 See Troubleshooting section in welding power source manual Check plug PLG50 PLG51 and PLG52 connections see Section 4 12 Wire feeds erratically Check position of Motor Torque switch see Section 5 11 Adjust drive roll pressure if necessary see Section 4 14 Replace or clean drive rolls as necessary see Sections 6 2 and 6 3 Align drive roll with opening in gun conduit fitting and groove in bearing see Section 6 3 Arc varies and welding wire is kinked when feeding out gun Place Motor Torque switch in low torque position if welding with 030 0 8 mm aluminum welding wire see Section 5 11 Pressing gun trigger will not feed wire wire is not energized shielding gas flows and Jog switch activates motor Reset circuit breaker CB1 see Sectio
68. 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 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s Symbole graphique d avertissement Attention Cette pro Le 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 Ce groupe de symboles signifie Avertissement Attention Risques a g p d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer 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 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 entrainer 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
69. hazard 4 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 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 An LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle ee e 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 Put on grounded wrist strap BEFORE handling ASS boards or parts So e Use proper static proof bags and boxes to store move or ship PC boards E 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 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 A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause bi
70. ie dis 206190 1 16 in 1 6mm 1 S nro et 206 191 068 in 1 7 mm or 1 16 in 1 6 mm Aluminum Wire 1 Table 9 3 Extra Heavy Duty FasTip Contact Tips 22 ador ges 199 605 085 in 0 9 mm 1 SIO Nath aah lei 199 606 040 in 1 0 mm or 035 in 0 9 mm Aluminum Wire 1 BB PM e 9198851 045in 1 2 mm seg h e ttt aa aa 1 Ke 198 852 052 in 1 3 mm or 3 64 in 1 2 mm Aluminum Wire 1 RC RTE 198 853 1 16 in 1 6 mm 1 i e Ar aa 198 854 068 in 1 7 mm or 1 16 in 1 6 mm Aluminum Wire 1 Table 9 4 Tapered FasTip Contact Tips E At dE 9209025 080 in 0 8 mm 1 rd oa 9209026 035 in 0 9 mm 1 iecit te 4209027 30 045in 1 2 MM iu beber dar Eed Aa a Role 1 EE 209028 3 64 in 1 2 mm 00 t ttt e eens 1 PU tante 209029 052 in 1 3 mm ARE En ae eler eter a E 1 EE 209030 1 16 in 1 6 MM s mc ex ER NENNEN AQ Waaa 1 OM 1581 Page 53 Item Part No No Description Quantity Figure 9 1 Consumables Flowchart Continued Table 9 5 Value Multi Turn Contact Tips Mo od 071 825 030 in 0 9 mm
71. ier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 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 C Miller
72. ir en pr sence de vapeurs et former des gaz haute SES 3 d el ment toxiques et irritants Toujours v rifier la terre du cordon d alimentation V rifier et s assurer 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 de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions vanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxi ques en cas de soudage OM 1581 Page 5 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 d air homologu LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et 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 provo quer des br lures dans les yeux et sur la pea
73. 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 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 alimentationest 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 des 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 SUR Arm Arm nn L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op r
74. lve Use flowmeter to control shielding gas flow at the feeder The scale on the flowmeter is in cubic feet per hour CFH Read gas flow at the widest part of the float in the meter Rotate valve to change gas flow as necessary A regulator is still required on shielding gas supply with this option S 0659 5 11 Internal Controls 3 DES LOW TORQUE 4 BRAKE RELEASE i HIGH TORQUE Open left side door 1 FuseF1 See Section 6 11 2 Circuit Breaker CB1 See Section 6 11 3 Motor Torque Switch Use switch to select the force used to push wire The up position is for low force or torque The down position is for high force or torque H welding wire appears to be kinked nicked or damaged place Switch in low torque position 4 Brake Release Button Whenever power is On and the welding power source is energized button may be pressed to release spool brake so wire spool can turn freely Close and latch door Ref 151 779 Ref S 120 552 A OM 1581 Page 27 5 12 Gun Controls 1 Gun Trigger Press trigger to energize welding power source contactor if applica ble start shielding gas flow and begin wire feed For shielding gas preflow and post flow partially press trigger before and partially release after welding 2 Wire Speed Control Use control to adjust wire feed speed The numbers around the control are for reference only Ref 151 666 E 5 13
75. n 6 11 Feeder feeds wire but remains in run in mode after arc initiation Route weld cable through current sensing relay see Section 4 8 If constant current CC welding be sure PLG5 is in EXT position on PC1 and voltage sensing lead is connected see Section 4 10 If constant voltage CV welding be sure PLG5 is in INT position on PC1 and that voltage sensing lead is not connected see Section 4 10 Feeder feeds wire but switches from weld mode to run in mode while CV welding with voltage sensing lead installed Be sure PLG5 is in INT position on PC1 Disconnect voltage sensing clamp from workpiece see Section 4 10 Shielding gas leak through gas valve in gun Reduce shielding gas pressure at regulator flowmeter Do not exceed 50 psi 345 kPa OM 1581 Page 37 B Gun Trouble Trouble Remedy No weld output gun feeder does not work Secure 115 VAC input plug in 115 volts ac receptacle see Section 4 11 Place Power switch on welding power source in the On position Erratic weld output Tighten and clean all connections Pressing gun feeder trigger does not en ergize weld control welding wire is not energized shielding gas does not flow Secure plug from gun control cable into 10 socket receptacle on wire feeder see Section 4 6 Wire does not feed burnback in contact tip Reinstall current pick up tab if applicable see Section 6 2
76. nd tighten threaded collar 2 Gas Hose Connect to Gas fitting on feeder 3 Weld Cable 4 Weld Cable Terminal In Feeder Connect gun weld cable to weld cable terminal in feeder 5 Wire Conduit 6 Thumbscrew 7 Wire Conduit Block 8 Strain Relief gt For guns that have wire con duits with replaceable liners the strain relief will need to be removed from the control box Loosen thumbscrew and insert conduit through wire opening until it bottoms against block Trim liner if necessary as close to the rolls as possible Tighten thumbscrew Close and latch door Left Side Tools Needed XT 5 8 3 4 in 145 432 C Ref 802 536 E Ref 151 778 B OM 1581 Page 13 4 7 Water Cooled Gun Connections Left Side Tools Needed IT 5 8 1 1 8 in 1 Gas Hose Connect to Gas fitting on feeder 2 Water Hose Connect to water to gun fitting on feeder left hand threads 3 Wire Conduit 4 Thumbscrew 5 Wire Conduit Block Loosen thumbscrew and insert conduit through Wire opening until it bottoms against block Trim liner if necessary as close to the rolls as possible Tighten thumbscrew 6 Gun Control Cable Insert plug into gun control recep tacle and tighten threaded collar 7 Strain Relief Remove strain relief as shown 8 Power Water Cable 9 Strain Relief gt For guns that have wire con duits with replaceabl
77. nd 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 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 1581 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 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 S
78. ndard 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 c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance 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 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 SPECIFICATIONS 3 1 Wire Feeder Specifications Specification Description Type Of Input Power Control Circuit Voltage Provided At Gun Wire Feed Speed Range Overall Dimensions Maximum Spool Capacity Cooling Method Weight
79. ociety 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 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
80. of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e 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 Insulate work clamp when not connected to workpiece to prevent contact with any metal object 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 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 local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator
81. ontact 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 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 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 When making input connections attach proper grounding conduc tor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill AEN 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
82. ource is equipped with matching 14 socket receptacle insert plug and tighten threaded collar Proceed to Section 4 13 If plug PLG5 will not connect to CC welding power source receptacle use the following pin information and Section 4 12 to replace PLG5 with a suitable plug Pin Pin Information A B Contact closure to A completes contactor control circuit Remote l 115 volts ac Contactor J Contact closure to completes 115 volts ac contactor control circuit G Circuit common for 115 volts ac circuit C 10 volts dc output to remote control Remote D Remote control circuit common Voltage Control E 0 to 10 volts dc input command signal from remote control K Chassis common The remaining pins are not used Ref S 0004 A Ref 151 772 OM 1581 Page 18 4 12 Replacing 115 VAC Contactor Control Plug With Customer Supplied 5 Pin Or Twistlock Plug gt e 1 115 VAC Contactor Control Plug PLG5 2 Contactor Control Cord 3 115 VAC Cord Find and label cords by following leads to back of PLG5 Contactor control cord connects to pins A amp B of PLG5 115 VAC cord connects to pin J of PLG5 Cut off plug PLG5 4 5 Pin Plug 5 Two Prong Twistlock Plug For connections shown in Figure 3 3 or Figure 3 4 install 5 pin or twistlock plug onto contactor con trol cord For Figure 3 2 connection obtain plug to match contactor control receptacle on welding power source
83. peed lower than welding wire feed speed Set control at O zero for scratch start Ref 176 700 A 5 5 Jog Switch 50 40 50 70 8 0 90 100 I 0 0 ta 1 Jog Switch Use switch to energize drive mo tors in feeder and gun without ener gizing welding power source con tactor When switch is held up in Jog position wire speed is set by Wire Speed Control on gun 5 6 Voltage Wire Speed Switch And Meter Optional ters to operate Volt sensing lead must be con nected to workpiece for me v olo OJO 1 Voltage Wire Speed Meter 2 Voltage Wire Speed Switch When switch is in Voltage position and operator is welding meter dis plays arc voltage Cable resistance and poor connections may cause displayed voltage to vary slightly from actual voltage at welding arc When switch is in Wire Speed posi tion and operator is welding meter displays preset wire speed in in ches per minute This wire speed is set by Wire Speed Control on the gun During run in portion of weld cycle meter displays run in speed as se lected on Run In Speed control on feeder see Section 5 4 When welding Direct Current Elec trode Negative DCEN meter does not display accurate output voltages however meter displays accurate wire speed values OM 1581 Page 25 5 7 Spot Controls Optional 2t02 5 S CONT JOUS TIME RANGE 1 Spot Continuous Switch
84. r Shldr Nyl 1 000 Od X 375 Id Air cooled Model 1 SIG be EE 010 910 Washer Flat Stl Sae 375 Air cooled Model 2 LIAE dom Da Hi na naa 601 872 Nut Stl Hex Full 375 16 2 Ob su ID ao aba 602 213 Washer Lock Stl Split 375 1 Eu e PE 602 243 Washer Flat Stl Std 375 1 ny 151663 Fitting Plug Water Block 1 L SV AC RE ER 151 664 Fitting Diverter Water Block 1 43 88 arrete 444151 662 Fitting Pipe Brs Plug Hex 125Npt 2 68 ox ems 4 4073 432 Fitting Brs Barbed M 3 16Tbg X 1 8Npt 2 v BB haaa SY isis 011 770 Switch Tgl Spdt 5A 125V 1 ha FO IEE ene 113 565 sis DOO Bl ise bet erbe uet edu rre ere atr bancos tt de aos 1 uso d stmt dae EEN Fig 8 2 Motor amp Wire Drive 1 DE GER 010 546 Bushing Snap in Nyl 375 Id X 500Mtg Hole 1 73 REED 140786 Switch Reed 1 sept M sot oss 010 498 Bushing Snap in Nyl 625 Id X 875Mtg Hole 1 Zb ET v 012 663 Fuse Mintr GI Slo blo 3A 1
85. rce lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip 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 LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour la sant 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 A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de Sols grilles ou chafaudages en 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 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 soud
86. ription 75 76 77 78 143 223 D Figure 8 1 Main Assembly OM 1581 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly SIS PAGKA AYA Noy ath 089 572 GatchiBINK 06k oe dre e ter terae AG Aa aaa 2 SP MANGIN ne he 112167 Insulator Door iio p3 Le dan ga eech at de Ae aa de 1 M AA 134327 Label Warning General Precautionary 1 E AA ed A ee EES 1 A n 126415 Clamp Saddle noel eter m dette a ME mat 1 MO alt eraf and 126416 Handle Molded 1 xU ausu eia 058 427 Ring Retaining Spool 1 D lt rec 602 233 Washer Flat Stl 250 Id X 875 Od X 062Thk 1 9 ES 057 543 Spring Cprsn 845 Od X 091 Wire X 1 500 1 SdO Ii 113168 Washer Locking 2 elles mets 058 428 H b Spool serere Jn tei Ue ee x a cR ca Ue Rd ds 1 Ma 089 561 Washer Anti turn Stl 1 E PE 058 424 Washer For Brake 1 Ads mama 151 697 Strip Brake Surface Anti turn 1 A ner 112 198 Shroud Spool Wire 12 In 1 a NG ersten 030 170 Bushing Snap in Nyl 750 Id X 1 000Mtg Hole 1
87. rks 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 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 adjacent 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 h
88. rs Barbed Nipple 1 4Tbg 2 kc Ed Rn eU aa 010 606 Fitting Hose Brs Nut 625 18Rh 2 a 056 112 Fitting Hose Brs Ferrule 475 Id X 718 Lg 2 To PP 603 106 Hose Nprn Brd No 1 X 250 Id Order By Ft 10ft Lu B nr are is 198 891 Cable Control 15 Ft 15A amp W Models 1 E PLG20 217 292 Housing Plug Pins Service Kit d Le Grues e ERE 198 810 Cable Control 30 Ft 30A amp W models 1 j iW PLG20 217292 Housing Plug Pins Service Kit d Mud AA O e rr 137 476 Cable Power Water Out 15Ft 15W Model 1 MAG EL he 137 477 Cable Power Water Out 30Ft 30W Model 1 RX LA 073 476 Clamp Strap Rbr 5 Holes 375 Wide X 4 625 Lg 15A amp W Models 6 A 0 as ces 073 476 Clamp Strap Rbr 5 Holes 375 Wide X 4 625 Lg 30A amp W Models 13 ss KA 162041 Bearing Block Assembly 1 WENNS 604 638 Screw Cap Stl Sch 6 32 X 375 8 dd 143 480 Screw 6 32 X 625 Soc Hd Hex Stl 1 EK pm sant 136 135 Roll Drive Vk Groove 023 1 16 Wire Consisting Of 1 AS 604 612 Screw Set Stl Sch
89. rth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq gt Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling P MOVING PARTS can cause injury Keep away from moving parts such as fans NG e 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 keep spark gaps at correct setting a
90. s quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser 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 excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits 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 cifi 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 Le couvercle du d tendeur doit toujours tre en place sauf lors que
91. s Model and serial number required when ordering parts from your local distributor OM 1581 Page 50 17 Hardware is common and not available unless listed 8 Ref 800 434 G Figure 8 5 Head Tube Assembly Of Pistol Grip Gun Item Part No No Description Quantity Figure 8 5 Head Tube Assembly Of Pistol Grip Gun Figure 8 4 Item 15 MEI UN TN CR TT 199 613 Nozzle Brass 5 8 In Orifice Tapered 1 bi uae EIAS SE WAKWE Tip Fastip See Section 9 1 obo radins 227 749 Diffuser 281 312 Od Collar Fastip 1 8 Rec Edge 1 E 232 284 Insulator Nozzle Collared Diffuser 1 VE CD vba e Pact ga 219 794 Jacket Outer Insulating 1 na 0 eu ua 219 795 Insulator Barrel Pistol 1 EE 219 796 Head Tube Air Pistol Brazed 1 M EO CNET 134 800 O ring 614 Id X 070cs 2 RC EE es 203 675 Manifold Water 15w 4 30w Models Includes 1 oi dO au 175946 O ring 614 Id X 070cs 2 oer L Ka R Eai va 135 128 Screw Cap Stl Sch 6 32 X 1 000 15 30w Models 2 nai TA repu In 231 532 Head Tube Assy Water Cooled Pistol HD 15 30w Models
92. t BRASS 199 610 OR sa COPPER 199 615 EO STANDARD 5 8 ORIFICE BRASS 199 613 OR Sa COPPER 198 855 C STANDARD 3 4 ORIFICE BRASS 199 611 OR COPPER 199 616 Las SCREW ON COPPER TAPERED NOZZLES CJ C 8 res 1 2 ORIFICE 209 036 nd C IB lod 3 8 ORIFICE 209 035 SLIP ON COPPER TAPERED NOZZLES 1 2 ORIFICE 209 033 3 8 ORIFICE 209 034 HEAVY DUTY FASTIP CONTACT TIPS 030 1 16 WIRE CNO 045 206 179 1 16 4206 190 TAPERED FASTIP CONTACT TIPS 023 1 16 WIRE E MO TAPERED FASTIP CONTACT TIPS 023 1 16 WIRE L MO D ND SPOT DIFFUSER 209 099 VALUE MULTI TURN DIFFUSERS FLUSH STANDARD INSULATOR 199 622 1 8 RECESS 199 621 EXTRA HEAVY DUTY DIFFUSERS FLUSH 199 623 1 8 RECESS 198 857 STANDARD DIFFUSERS EI FLUSH 231 512 ENT L 198 856 COLLARED INSULATOR XR A Spoolmatic Barrel Assy 1 8 RECESS STD ON ALL GUNS 227 749 CAT 1 4 RECESS 231 511 SLIP ON TAPERED DIFFUSERS E sf FLUSH 209 032 p 232 284 TAPERED INSULATOR 6 0 STRAIGHT 221 087 XR W Barrel Assy S in 6 0 STRAIGHT 4221 519
93. tall top cover Tools Needed Lm Ref 151 599 F 6 5 Replacing Or Cleaning Feeder Drive Roll Bearing AN Tools Needed paa Tum Off wire feeder and welding power source Pressure Roll Assembly Retaining Ring Mounting Arm Hinge Pin Screw Shoulder Washer Drive Roll Bearing NO Oa nm Remove as shown Use a wire brush to clean bearing Reinstall and tighten screw Close pressure roll assembly Close and latch door 151 778 Ref 151 781 B OM 1581 Page 32 6 6 Changing Gun Contact Tip Remove nozzle Ge Cu 1 Nozzle 2 FasTip Unscrew FasTip Install new FasTip Ref 150 437 A 6 7 Removing Diffuser In Air And Water Cooled Pistol Grip Guns 4 WARNING WATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality e Turn Off welding power source and water supply before working on gun Stop engine on welding generators e Always point gun downward when removing water cooled barrel to keep water out of gun parts Wipe gun dry before putting it back together Y Turn Off welding power source Pa Ge ee 1 Nozzle 2 FasTip To remove see Section 6 6 3 Diffuser Remove diffuser and replace Air Cooled Head Tube Assembly Tools Needed LS 2 sin
94. u Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap 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 tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels DES PIECES CHAUDES peuvent provoquer des br lures graves Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures 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 tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact ac

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