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Miller Electric SuitCase 8VS User's Manual

1. 203 029 C 4 AK FED FRONT PANEL 1 OFF PLG7 RC7 cB1 me J7 1 lt Jf Ne SENSE LEAD 051 47 6 lt gt C O DRIVE HOUSING i A W 1 23 TARA O WELD CABLE Cr Cla F i S 18 S S S4 Joc o F E U M wo owl o T i Y yoy E 8 8 8 i 42 Aa o 2 a o ES Re RC54 2 gt pose RC35 1 gt RCS4 5 gt iae poai 7 TRIGGER HOLD ggasi oE gay az 84 L E _2 RC31 PLG31 a gt gt 4 i RC54 6 gt gt 3 lt RC31 2 aea RC35 3 gt PLGB RCB RC54 4 gt 1 gt lt R031 3 RC35 4 1 21 pipi OPTIONAL RC54 3 gt RCS4 1 gt gt L 2 3 lt Be RC55 2 75 IS z 8 lt lt RC55 3 PURGE s TP1 gy ROS PLGB y RC2 S2A RC50 4 gt gt 1 1 1 TR J9 Soe J RSS PCI Rc50 9 gt gt 22 gt 2 gt M2 13 IF e MOTOR CONTROL TS Sg RGSS 2 FEDER OAR m o i RC50 6 gt gt RCSQ PLCSO OL 928 EAE Lu cc T zz 12 RC52 PLC52 RC50 7 gt gt 7 lo 2 RCS3 PLGS3 I 53A RC54 PLC54 RC51 1 gt gt E RC55 PLG55 cV i RC56 PLG56 4 i 70 RC57 PL657 RC56 1 gt lt RO53 1 ee 47 25 39 1 651 r ACTA 1 i T7 T T 1 13 lt lt RC52 2 2 2 2 RC15 5 ee Bo lt s lt 8 lt lt RC50 11 RC56 3 gt m i E coc RC15 10 2 ig Sul ce E __ RrR0 8 24 165 t v 2 d i RC18 9
2. 1 Dre dum s 093 551 Knob Pointer Meter Option 1 OT dati tet imn 210854 Insulator Motor 1 nn 08 dts i ASA 211989 Fitting W Screen 1 t Trigger Hold feature optional in non CE models standard in CE models Optional When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1599 Page 22 Figure 8 2 Drive Roll amp Wire Guide Kits 2 Drive Roll NOTE F Base selection of drive rolls upon the following recommended usages V Grooved rolls for hard wire U Grooved rolls for soft and soft shelled cored wires U Cogged rolls for extremely soft shelled wires usually hard surfacing types V Knurled rolls for hard shelled cored wires Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Drive Roll Inlet PartNo Type Wire Guide 030 in 030 in 040 in 040 in 052 in 079 597 053 698 056 193 OA La M 085 in 056 192 045 in 056 193 052 in 056 193 1 16 in 056 195 045 in 056 193 052 in 083 317 083 490 U Cogged 056 193 1 16 i
3. C C see Section 5 1 Uu 100 V DC Hz Us 100V 1 500 X 100 ST 181 678 3 3 Symbols And Definitions NOTE MEN Some symbols are found only on CE products e Output lt gt Input A Amperes V Volts X Duty Cycle olo Wire Feed o6 Percent P odd Protec Cold Jog Inch To Lv Input Aja wards Workpiece A Purge By Gas ica a Constant Current Circuit Breaker Constant Voltage gt Slow Trigger Hold Off m Trigger Hold On 2 Rent Increase di a Read Instructions U 4 Primary Voltage U 2 Mu FORE H Z Hertz l Primary Current OM 1599 Page 10 SECTION 4 INSTALLATION 4 1 Specifications Type of Ana Wire Feed Wire Type E gt ip Max Wire dise Input Speed And Re Spool Weight Power Source Range Diameter Circuit Rating Capacit Dimensions Type 9 Rating pacity Solid Steel 023 062 in Length 15 5 8 in Open Circuit Constant 50 700 ipm 0 6 1 6 mm 397 mm Voltage CV 1 3 18 Stainless Steel 330 Amperes MA A DS eae Or Constant mpm 023 052 in At 60 23 a ER A d i gt Ko Volts DC Current CC Depending On 0 6 1 3 mm Duty Cycle 9 DC Arc Voltage Flux Cored Height 14 1 2 in 030 052 in 368 mm 0 8 1 3 mm 4 2 Gun Recommendation Table Process Gun GMAW Hard or Corded Wires M25 Or M40 FCAW Self Shielding Wires FC 1260 4 3 Equipment Connection Diagram
4. Ref 802 706 A OM 1599 Page 17 6 3 Troubleshooting ome Trouble Remedy Wire does not feed open circuit voltage available Check circuit breaker CB1 Reset CB1 Unit overheated Allow unit to cool Check sensing lead connection Check gun trigger plug connection Check gun trigger See gun Owner s Manual Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or worn drive roll see Section 4 4 Remove weld spatter around nozzle opening Replace contact tip or liner See gun Owner s Manual Wire feeds as soon as power is applied Check gun trigger See gun Owner s Manual Wire feeds when Jog switch is pressed but not when gun trigger is pressed Check gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Wire stubbing on low end using a con stant current power source Make sure CC CV switch is in CC position see Section 5 1 Increase output setting of power source Gas does not flow or does not stop flow ing wire feeds Check gas valve Have Factory Authorized Service Agent check control board PC1 Wire remains energized after trigger is released Check contactor W1 to see if contacts are frozen closed OM 1599 Page 18 SECTION 7 ELECTRICAL DIAGRAMS
5. e Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection 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
6. 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 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 1599 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 Associat
7. examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 1599 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 pr
8. going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face 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 Ga
9. gt 3 lt T RC50 12 RC56 4 gt 44 WARNING e Do not touch live electrical parts SSA c 1 L 2 a Disconnect input power or sto of n 64 o put p p REIS S Kel x Lo SN engine before servicing RC15 7 gt p lt 2 lt pas ao n 1 RC56 2 er Cu Do not operate with covers removed OPTION RASE 1 P E m S n n o ELECTRIC Have only qualified persons install RC15 1 5 lt lt RC51 5 LO 1 1 B Lo TU Pi ROB 7 S y SHOCK HAZARD use or service this unit N R Feeder Ire For W ircuit Diagram Figure 7 1 C OM 1599 Page 19 SECTION 8 PARTS LIST Hardware is common and not available unless listed 802 675 E Figure 8 1 Complete Assembly 28 OM 1599 Page 20 Item Dia No Mos ia Description Figure 8 1 Complete Assembly Re 202 695 Nut HUD TTT DELE NE E 172919 Knob Brake Adjust a EE Deleted reist eS EOS UE MeL Ma ales gates RU a deals D AA 172 918 SDNINQ ie O et uns SD ert nes habeas me dota 201 309 Washer Anti Turn ccc eee nee enn nes ROAD e Rent Deleted ss a Boe dde sn Asp RE A E iE 202 696 HUD Spool decada ee ere re A Blea ue ote O amas 058 424 Washer Fibre Brake Mo TEES 225 568 Shroud Wire OND amuse 200 615 Support Spool s
10. slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipmentthat has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 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
11. 085 244 Washer Cupped 328 ID x 812 OD x 16ga x 125 Li 1 DUO denied 089 477 Spring Cprsn 770 OD X 100 Wire X 715 Pld 1 DEC IDCM 085 243 Knob Adjust Tension 1 250 Dia X 312 18 Thrd Stl 1 DO metre 200 626 Bracket Mtg Contactor 1 60 W1 192809 Contactor 12VDC 1pst On off Magnetic Blow Out 1 HO s coc ees 200 625 Bracket Mtg Contactor Spool 1 E lt s oru eae Das 201378 Insulator Capacitor cette etn nes 1 63 C1 2 200606 Capacitor Elctlt 1200 uf 300 VDC Can 1 39 Dia 2 25764 faisant 210 920 Bracket Capacitor Support 1 65 PC1 223167 Circuit Card Assy Motor Control 1 25466 ZR arses 201434 Cover Capacitor 1 ET ise Pcia 200 903 Ckt Card Assy Trigger Hold Trigger Hold Option 1 097 132 Standoff No 6 32 x 375 lg Trigger Hold Option 1 E 098 691 Standoff No 6 32 x 500 lg Trigger Hold Option 1 Vega put AM OR ashe 203 067 Plug Assy Elect Trigger Hold Option 1 DE e Li m UL 206 542 Circuit Card Assy Meter Meter Option
12. 1 Retaining Nut 2 Hub Tension Adjustment Nut Remove retaining ring and install spool so hub pin fits spool hole Re install retaining nut Adjust tension nut so only a slight force is needed to turn spool Threading Welding Wire 3 Pressure Assembly Adjustment Knob Lay gun cable out straight Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun Close and tighten pressure assem bly Press Jog switch until wire comes out gun Feed wire against wooden surface and tighten knob so wire does not slip Cut off wire and close door Tools Needed Z2 ghein 802 706 A Ref ST 159 048 A S 0627 A OM 1599 Page 14 SECTION 5 OPERATION 5 1 Controls For Non CE Models 1 Power Control Switch 2 Trigger Hold Switch Optional This unit offers an optional trigger hold function which is turned On or Off with a front panel toggle switch Depress the upper part of the switch turns trigger hold On to weld with out holding gun trigger throughout the weld cycle VAS To start weld press and release gun trigger To end weld press and re lease gun trigger PURGE TRIGGER POWER HOLD Depress the lower part of the trigger hold switch to turn trigger hold Off 1 raqa FP rard 3 Purge Switch L L L L Press switch to momentarily ener LJ CO GA gize gas solenoid and purge air from gun and
13. 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les 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 8 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 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 DEFINITIONS 3 1 Warning Label Definitions Warning Watch Out There are possible h
14. 32 X 1 710 Lg 438 Dia Stl Fem 1 41 TP1 201441 Cable Assy W Thermostat 1 E Rp 200 628 Lead List Large 1 MEE 600 322 Cable Weld Cop Strd No 2 0 Epdm Jkt 48 M1 225341 Motor Gear 24VDC 150RPM 24 1 Ratio 1 mA voulu 079 624 Screw 375 16 x 2 25 Hex Hd pln Stl Pld 1 PAD i sua 173 616 Cover Right Angle Motor 1 2x40 iussu 144 712 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 1 ox T usages 215 719 Stand Off No 10 32 X 1 000 Lg 375 Hex Stl M amp f 1 wit 4B Russe 216 684 Insert COMER suere rane rue at ST xe D Be a RUE ed aA Frac 1 x49 antes eoe 182 788 Housing Adapter Gun Feeder 1 A ati 124 778 Knob T 2 000 Bar W 312 18 Stud 1 000 Lg Plstc 1 sub EN EN 173619 Carrier Drive Roll W Components 24 Pitch 10mm Shaft 1 Es ARS A EN 172075 Carrier Drive Roll W Components 24 Pitch 1 uc PEE E 173620 Bushing Motor Mtg 3 A TTT 010224 Pin Spring Cs 187 X 1 000 1 SAO s o Te AM 089 562 Fastener Pinned cc etn n eee n eas 1 ep OM gr te
15. A Turn Off wire feeder and X NN OO Q E ND welding power source Stop engine on welding generator Constant Current CC or Constant Voltage CV Welding Power Supply Negative Weld Cable Positive Weld Cable Workpiece Wire Feeder Voltage Sensing Clamp Gun Gun Trigger Receptacle Gas Hose Gas Oylinder 803 625 A OM 1599 Page 11 4 4 Installing And Aligning Wire Guide And Drive Rolls VAS Tools Needed 3 16 in I 3 8 in Installing Wire Guide And Drive Rolls 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier 3 Drive Roll Slide drive roll onto drive roll carrier Turn nut one click Y E LE es p DO Repeat procedure for top drive roll 4 Inlet Wire Guide Screw 5 Inlet Wire Guide Loosen securing screw Install inlet guide so inlet guide screw is TC i 5 Installing Wire Guide centered in groove in guide or so tip And Drive Rolls is as close to drive rolls as possible without touching Tighten screw Aligning Wire Guide And Drive Rolls View is from top of drive r
16. California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 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 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 equipmenta
17. Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Machinery Directives 98 37 EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 5 Wire Feeders IEC 60974 5 Ed 1 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 2 1 Degrees Of Protection Provided By Enclosure IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within Low Voltage Systems Part 1 Principles Requirements and Tests IEC 60664 1 Ed 1 1 The product technical file is maintained by the responsible Business Unit s located at the manufacturing facility dec wire 6 05 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 inform
18. TE 1 nternal side View Ml A BH ME H uH 4 ME B 5d Mp jg s g H oS NIS JE FH jg Dip Switch Position Ref 803 626 A Ref 802 706 A Ref 803 124 OM 1599 Page 15 5 2 Controls For CE Models AN 40 60 4 OJ 20 80 ojo Front Panel LO olo cech 7 p I ojo HI ojo cv Internal Control Panel D mu O Internal Side View 1 Power Control Switch 2 Trigger Hold Switch Depress the upper part of the switch turns trigger hold On to weld without holding gun trigger throughoutthe weld cycle To start weld press and release gun trigger To end weld press and release gun trigger Depress the lower part of the trigger hold switch to turn trigger hold Off 3 Purge Switch Press switch to momentarily ener gize gas solenoid and purge air from gun and to adjust shielding gas regulator 4 Wire Speed Control Use control to adjust wire speed within range selected by switch 5 Jog Switch Use Jog position t
19. UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit een eee e eee e eee eeees 8 2 5 Information sur les champs lectromagn tiques 8 SECTION S DEFINITIONS io A Ae EE 9 3 1 Warning Label Definitions 42 220882 9 3 2 Manufacturers Rating Label For CE Products 10 3 3 Symbols And Definitions 10 SECTION 4 INSTALLATION x Ya y c RISRRG Pee 4r E xe ARR i gw NR messe nan ELE 11 4 1 Specifications stereo aie A RR GP EN QURE QUE QMERE RE SD ERE Ed 11 4 2 Gun Recommendation Table 11 4 3 Equipment Connection Diagram sssss sessa reren rrer eee t eens 11 4 4 Installing And Aligning Wire Guide And Drive Rolls 12 4 5 Connecting Welding Gun And Voltage Sensing Clamp 13 4 6 Connecting Shielding Gas 44424220 13 4 7 Co
20. close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby 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 1599 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
21. compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This 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
22. 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 accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de 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 co
23. legal rights and other rights may be available but may vary from province to province miller_warr 1 05 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2005 Miller Electric Mfg Co 10 05 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066
24. off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable 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 t
25. 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 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 Encas 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
26. 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 source 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 vapeur
27. 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 peau 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
28. www MillerWelds com C Miller
29. 28 near aia iw e qme Ri ema o de ein de DC PE eee 213 995 Cable Trigger 20 In DA rau bade aad vate 049 455 Cable Port No 18 2 C Type sjo nprn Jkt VERA RU eH RC2 048 834 Conn Circ cpc Clamp Str RIf Size 11 3290D LEE beads ae RC6 115 090 Housing Plug Pins Service Kit 080 328 Rept W Skts Free Hanging Service Kit ERES PLG6 115094 Housing Plug Skts Service Kit PLG14 227 529 Housing Plug Skts Service Kit OO sea 138 044 Bushing Strain Relief 120 150 Id X 500 Mtg Hole D I 010 476 Bushing Strain Relief 360 Id X 625 Mtg Hole ROD Semi 214009 Panel Front Lower DE Een 214010 Panel Front Lower Backing Plate Quantity OM 1599 Page 21 No Mkgs No Description Quantity Figure 8 1 Complete Assembly Continued sx OT quaauesisarsess 081 895 Nut 010 32 Rubber 75dia 811 Insert In 38hole 4 2990 Lia dade 200 604 Chassis Control BOX 1 CC 200 613 Stand off No 10 32 X 1 835 Lg 500 Hex Stl Fem 3 ssl oci pets 200612 Stand off No 10
30. 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of 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
31. Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied 2 Shielding Gas Cylinder 3 3 Valve v Rear View 4 Flowmeter Close valve on cylinder when fin pus ished welding E Li s Tools Needed 3 e8 BIB in 801 155 A Ref 802 770 OM 1599 Page 13 4 7 Connecting Weld Cable Pa Internal Side View A From Wire Feeder A Turn Off wire feeder and welding power source Stop engine on welding generator 1 User Suppled Weld Cable Follow wire manufacturer s recom mendations for weld cable polarity 2 User Suppled Male Connector 3 User Suppled Female Connector Push female connector over male connector and turn 1 4 turn clock wise Ref 132 808 F Ref 802 706 4 8 Installing And Threading Welding Wire Hold wire tightly to keep it from unraveling Sa Te CNN E Pull and hold wire cut off end WOOD Tighten JA Clockwise y Installing Wire And Adjusting Hub Tension
32. OM 1599 200 624M 2005 11 Processes MIG GMAW Welding Flux Cored FCAW Welding Description Ed D2 ES Wire Feeder CE OWNER S MANUAL File MIG GMAW gm N 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 3 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 A 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 pro
33. actical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som 3 05 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 La 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 d 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 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 entrain
34. ant 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 des 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 vo
35. ation given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard 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
36. azards as shown by the symbols Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation keep hands and metal objects clear 1 Electric shock can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 1599 Page 9 3 2 Manufacturer s Rating Label For CE Products For label location
37. d neues 201302 Spindle scis rk eee ep ere p uU XE elo ara 605 227 Nut 750 14 Knurled1 68 dia 41h Nyl UA 212058 Insulator Strain Relief Gas Valve T4 Eae aE 139 041 Bushing Strain Relief 481 617 ID X 1 115 Mtg Hole 15 LES 126 738 Guide Mtg pc Card 8 In Deep Channel 16 GS1 215284 Valve Gas W Fittings 12VDC 17 SR1 035 704 Rectifier Integ Bridge 40 Amp 800V 18 S3 55 200 633 Switch Rocker Dpdt 8A 125VAC On none on Black 19 ke ee he a 098 615 Hose Sae 187 ID X 410 OD X 19 000 20 icr reus 200 632 Nameplate Inner prior to serial no LB031537 non CE only 20 vc IMS 202 897 Nameplate Inner effective with serial no LB031537 non CE only 20 riura rouge 203 748 Nameplate inner CE only HOT arte 200 631 Panel Inner prior to serial no LB031537 Tom 202 854 Panel Inner effective with serial no LB031537 22 CB1 202 711 Circuit Breaker Man Reset 1p 7A 250V Fric Snapin 23 PR TO rre 200 617 Insulator Cover Wires DA me le Es eu denos 196 956 Label Warning Electric Shock And Pinch Wo
38. er guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 8 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sourc
39. er la mort instructions aff rentes pour viter tout risque Les instructions en e L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e 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 oe 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 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 sau err Porter un harnais de s curit si l on doit travailler au us du sol provoquer de
40. es Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated J ntellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes
41. floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 APA 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
42. he area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 1599 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
43. ion 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 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 1599 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 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
44. n 079 601 053 706 056 195 OM 1599 Page 23 Notes OM 1599 Page 24 Notes HART WELDING TECHNOLOGY t Start Your Professional Square East Troy Ohio 45373 Vet 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 OM 1599 Page 25 Notes DECIMAL EQUIVALENTS P e Oe Se 9 L OS Pe PT ve e 9 dez 06 6 5 P e e P 909 ve e 9 ve 9 0 60 33 6 3 ve e 6 eiz Q e o9 ve e 9 66 S o i OM 1599 Page 26 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2005 Equipment with a serial number preface of LF or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no oth
45. nform 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 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 1599 Page 6 distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin av
46. nnecting Weld Cable oooocccccocccccccc n rnrn r renr r reren r errar r rrarena 14 4 8 Installing And Threading Welding Wire 14 SECTION 5 OPERATION gt X a r X um RUM RRR RRR FERRE EINE ERE 15 5 1 Controls For Non CE Models 15 5 2 Co trols For GE Models ios D Here MR a 16 SECTION 6 MAINTENANCE amp TROUBLESHOOTING euu 17 6 1 Routine Maintenance ciere rh eer b Re eR Eni ERE EE La RR REOR as 17 6 2 Overload Protection And Thermostat Protection 17 6 3 Troubleshooting scena depo chad eee at ne eden HA ee a dnd 18 SECTION 7 ELECTRICAL DIAGRAMS 0occcococccc III nnn 19 SECTIONS PARTS LIST 2 2 2 2 A tenants 20 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products N OTE E This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 Bt European Contact Signature Declares that the product S u i tC a S e 8VS conforms to the following
47. o momentarily feed welding wire at speed set on Wire Speed control without ener gizing welding circuit or shielding gas valve 6 HI LO Range Switch Use switch to select high or low wire speed range High range is 100 to 700 ipm Low range is 50 to 350 ipm 7 CC CV Switch Use switch to match wire feeder with welding power source output Close and latch door Ref 803 626 A Ref 802 706 A Ref 203 745 Ref 203 749 OM 1599 Page 16 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance NH NE E ad A Disconnect power Maintain more often E before maintaining during severe conditions 3 Months WARNIN WARNIN Replace Damaged Or j Replace Damaged Unreadable 7 Gas Hose Labels Repair Or Replace Cracked Cables And Cords ad Blow Out Or ive Vacuum Inside Rolls N e A Turn Off wire feeder and X welding power source Stop engine on welding generator 1 Circuit Breaker CB1 CB1 protects wire feeder from over load Correct problem and reset CB1 Close and latch door Thermostat Protection Unit has internal thermostat protec tion and will not feed wire if over heating occurs see Section 6 3 m m D Internal Side View
48. olls look ing down with pressure assembly open 6 Drive Roll Securing Nut 7 Drive Roll 8 Wire Guide 9 Welding Wire 10 Drive Gear Turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Only bottom drive roll alignment is adjustable Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown Cleaning Drive Rolls Aligning Wire Guide And Drive Rolls Remove drive rolls and clean grooves using a wire brush Correct Incorrect 802 706 A Ref 132 808 F Ref 162 079 A Ref 180 967 OM 1599 Page 12 4 5 Connecting Welding Gun And Voltage Sensing Clamp N e A Turn Off wire feeder and Pi welding power source Stop engine on welding generator 2 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob insert gun end into block Position outlet wire guide as close as possible to drive rolls with out touching Tighten knob L ie Y ea 4 Gun Trigger Plug Y f 5 Gun Trigger Receptacle 6 Voltage Sensing Clamp Internal Side View 3 Connect voltage sensing clamp to workpiece SE C 4 6 Ref 802 706 A 802 768 A Ref S 0621 C 4 6 Connecting Shielding Gas 1
49. pareil SUR ar nn L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste RS 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 S 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 Remett
50. per maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in s the U S A ta 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 1 121 Symbol Usage sso e qu Vee Y e e A NO Y YU CEDE TE E A 1 1 27 Arc Welding Hazards tenere egre uer e Pe ate UG ne tes 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings e e e e eee eee aes 3 1 5 Principal Safety Standards san 4 1 6 EME Information 4 sieur ere rena de a nana Bus aa abe ee te dl ERR E Re RR E 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT
51. rdless 24 4x4 AA 225 567 Case Control Feeder Plastic REA AA 134 327 Label Warning General Precautionary non CE only n 178 936 Label Warning General Precautionary Wordless CE only MAN NM y ed E 200 007 Label Ironmate FC 1260 Consumables 25 R1 073 562 Pot Cp Std Slot 1t 2 W 10k Linear PO ao arces 202 179 Panel Assy Front non CE On 00 cece e eee eee 20 en sie ee ide 203 746 Panel Assy Front CE only 206 res 202 177 Panel Assy Front non CE only Trigger Hold Option S020 sornika aiina 206 962 Panel Assy Front Meter Option BM RRR Ear 200 639 Nameplate non CE only DT iste re 203 743 Nameplate CE only 0 0 cece eee nets DT e arrete 202 186 Nameplate non CE only Trigger Hold Option Da 206 902 Nameplate Meter Option 28 S2 84 200 640 Switch Rocker Dpdt 8A 125VAC On none On 29 Sd ius 111 997 Switch Rocker Spst 10A 250VAC On off O ie ee 193 920 Knob Pointer 840 DIA X 250 ID E teu data te ai 214 011 Cable Sensing 2 28
52. reles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs 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
53. s Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A k FIRE OR EXPLOSION hazard 4 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 nn 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 Puton 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 Z 5 1 4
54. s accidents mortels ou des br lures N un rar js t S l G mi SL s el nt a i xn graves Le circuit de l lectrode et de la pi ce est dese el que tous GS PANNEAUX et couvercies sant correcementen sous tension lorsque le courant est d livr la place p 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 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
55. s approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur 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 man
56. t once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area 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 1599 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1
57. to adjust shielding gas regu lator 4 Wire Speed Control Use control to adjust wire speed within range selected by switch 5 Jog Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve 6 HI LO Range Switch Use switch to select high or low wire speed range High range is 100 to 700 ipm Low range is 50 to 350 ipm 7 CC CV Switch Use switch to match wire feeder with welding power source output Close and latch door 8 Optional Voltage Wire Speed Meter 9 Optional Voltage Wire Speed Switch 10 Front Panel 11 Meter Hold Dip Switch If the switch is set to the HOLD posi tion the value will be held when you have welded for 8 seconds or more The meter will display the last weld value for 30 seconds after trigger is released or until retriggered which hi ever comes first WIRE SPEED PERCENT Front Panel Z LO olo cch 7 ojo Hol cvH Internal Control Panel Meter Meter Meter Meter Hold Hold Hold Hold OFF OFF ON ON Inches Meter Inches Meter Minute Minute Minute Minute Internal Side Vi LA
58. tre 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 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 ap
59. uel 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 agir en pr sence de vapeurs et former des gaz haute 2x 3 2 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 1599 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

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