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Miller Electric S-75D User's Manual

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1. 1 1 nib ilii Rioters 208 399 Potentiometer Cp Std Slot 1t 2 W 10k Linear W Frict Tabs 1 0 saa issus R us 224 597 Potentiometer Cermet Std Flat 3 75T 2 W 10k Linear 0 1 28 R70 224 597 Potentiometer Cermet Std Flat 3 75T 2 W 10k Linear 0 1 TIE PLG7 27 115091 Housing Plug Skts Service Kit O 1 ierra dus PLG11 61 131055 Housing Plug Skts Service Kit O 1 UR PLG17 158719 Housing Plug Skts Service Kit O 1 s 2 9 Aides idcm HP RS 211 989 Fitting W Screen His 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 223 605 Page 29 gt Hardware is common and not available unless listed OM 223 605 Page 30 8 See Table 9 1 For Drive Roll 8 Wire Guide Kits 9 10 804 186 A Figure 9 3 Drive Assembly Wire Item Part No No Description Quantity Figure 9 3 Drive Assembly With Motor Figure 9 1 Item 4 T uv iui be 224 772 Drive Assy Mechanical Lh 1 PERCIPIT 219 126 Screw Shld Stl Sch 375
2. 4 A DC anu Figures 9 3 9 4 Drive Assembly With Motor 1 ira Ee NE Ma eS 141 753 Hub 8 Spindle Assembly Consisting Of 1 na O etm Lus 058 427 Ring Retaining Spool 1 Le antenne 180571 Shaft Support Spool 1 oe ee ee eds 010 233 Spring Cprsn 970 Od X 120 Wire X 1 250pld 1 PERES DEN aream 057 971 Washer Flat Stl Keyed 1 500 Dia X 125thk 1 dO Se y eee 010 191 Washer Fbr 656 Id X 1 500 Od X 125thk 2 n 058 628 Washer Brake Stl 2 Aa bise es 058428 Hub Spool 1 Auc k ku 135 205 Nut Stl Siflkg Hex Reg 625 11 W Nylon Insert 1 M 200 556 Support Spool 1 DRAMO uu ra ke ela 201 781 Knob W Extension Clamp 1 EI s A EO EV 156 243 Clamp Motor Top 1 EEA MO ENE 219095 Spacer Motor Clamp 1 DO deis 200 552 2 BaSe narai asum aquya ahua ERU ERE Aere 1 Soa VO evi obe 134 306 Foot Rubber 1 250 Dia X 1 375 High No 10 Screw 4 PS AR DO rM nea E 200 557 St ffener
3. OM 223 605A May 2005 Miller MIG GMAW Welding Flux Cored FCAW Welding Gas And Self Shielded Description E ES Wire Feeder S 75S S 75D OWNER S MANUAL 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 2 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 ISO 00012000 of reliable service with proper maintenance And if f
4. 4 1 Specifications Welding s r Wire Type of Input Welding Power Circui IP Overall Maximum Wire Feed ircuit i i i Diameter Weight Power Source Type Rating Rating Dimensions Spool Weight Speed Range Range 24 Volts ac Constant 100 Volts IP 21 Length 27 in 60 Ib Standard 023 to 5 64 in 43 Ib Single Phase Voltage CV 750 Amperes 686 mm 27 kg Speed 50 to 0 6 to 2 0 19 5 kg 10 Amperes DC With 14 Pin 100 Duty Width 12 1 2 in 1400 ipm 1 3 mm 50 60 Hertz that Provides Cycle 318 mm to 35 6 mpm Volt d Height 14 i popu 356 ir Low Speed 023 to 1 8 in 48 Ib Feedback 20 to 400 ipm 0 6 to 3 2 21 7 kg 0 5 to 10 1 mm mpm 5 1 Site Selection Wire feeder shown is representative only and does not reflect actual unit A Do not put feeder where welding wire hits cylinder A Do not move or operate equipment when it could tip 1 Wire Feeder 2 Rubber Feet Choose slot that allows all rubber feetto sit securely on top of welding power source 3 Wire Spool Reel 4 Gas Oylinder w Hose And Regulator Customer Supplied I Shielding gas pressure not to exceed 90 PSI 620 kPa 5 Welding Power Source 6 Running Gear 802 806 A OM 223 605 Page 11 5 2 Rear Panel Connections And Rotating Drive Assembly 1 14 Pin Control Cable 10 ft 3 0 m 2 Shielding Gas Valve Fitting Connect customer supplied gas
5. 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 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 a ar nn L EMPLOI EXCESSIF peut CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste nn A 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 7 amp DES ORGANES MOBILES peuvent provoquer des blessures
6. e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geant le fil de soudage PAL DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels a gue 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 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 lect
7. 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 223 605 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou a 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 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
8. 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 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 tr
9. 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 223 605 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 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 cho
10. 16 X 500 X 1 000 Shld 2 goku ur idc 219098 Insulator Base Mtg Components 1 d emt atus 108 943 Screw 250 20x1 50 Hexwhd 61D Gr5 Pld 1 Oe uir ee crt 219 133 Screw 375 16x1 50 Hexwhd 81D Pld 1 O usura exa 093 664 Gear Spur Insulated Drive 1 d ge he gent 079 625 Washer Wave 500 Idx0 750 Odx 015t Stl Lbs 1 B ocesetesa ee ies 605 308 Ring Rtng Ext 500 Shaft X 035 Thk 1 gen Vd S eR 601 941 Screw 250 20x1 75 Hexwhd 61D Gr5 Pld 1 10 ost aai 219 132 Screw 375 16x2 00 Hexwhd 81D Pld 1 rt TEE 602 241 Washer Flat 281 Idx0 625 Odx 065t Stl Pld Ansi 250 1 Tas drea Een 181 221 Screw 250 20x 50 Button Hd Soc Stl Pld 1 195i Patients s 092 865 Key Stl 1215 1230 X 750 1 14 e rer mens 219 084 Pressure ASSy seek Va eee aer deoa er t dela E eani ien a RR 1 JD aka zoni bbs 144 172 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 1 10 aaah CH VR 219098 BIOOCK GAS vite Tuy teer trabe ted rd EOD T 2 iy erat ated RAJO dai 1 Ts id ana ean 219092 Clamp Pin Power 1 Teste 219 136 Lock PIA POWT aan dua e OVER te C II Un Q wU Cuy i
11. 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 DEFINITIONS 3 1 Warning Label Definitions A Warning Watch Out There are possible hazards as shown by the symbols B Drive rolls can injure fingers C 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 t
12. Base s uod ALL Ne Sa Sh oad A dei va 1 Lan L dane lini Figure 9 2 Control BOX 22 1 Fus s Ane ean 126 873 Bumper Polyurethane Polymer 500 Sq Adh Backed 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 223 605 Page 27 F gt Hardware is common and not available unless listed 12 802 945 D Figure 9 2 Control Box Quantity Item Diagram Part Model No marking No Description S 75S S 75D Figure 9 2 Control Box Figure 9 1 Item 21 UE dius 200 555 Wrapper Feeder Tae vel2 ad e ea he eru 134 464 Label General Precautionary For Static amp Wire Feed 1 1 vs P irre read te 178 936 Label General Precautionary Wordless CE WF CE Version 1 1 AC Ligue IU 115 443 Stand Off No 6 32 X 750 0 4 4 PC60 224 308 Circuit Card Assy Display W Program 0 1 IUIUS 010 494 Bushing Snap In Nyl 1 375 Id X 1 750 Mtg Hole Tuus A zer Geekdad g Init 057 357 Bushing Snap In Nyl 937 Id X 1 125 Mtg Hole Toe deb qupa EI 204 910 Cabl
13. CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles titiliS6S1 cultam late it oath sited nU NC E be N acne 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 Shira ni Rie Rer eR ae eae u ene oe EE E Raa 8 SECTIONS S DEFINITIONS 22 10 wie pete X x PIGEEIAERPIIDER GR pilots eed tere e usa 9 3 1 Warning Label Definitions 0 00 RII n 9 3 2 Symbols And Definitions 10 SECTION 2 INTRODUCTION 9 92 x v Im vere tee EIil E rates see kai ME ee eee de 11 4 1 Specifications s uoo na el Ahhh ee Gan QUERN QE QR Rd edu RAD DER 11 SECTION 5 INSTALLATION 5 22 EEA SA pees cease peed nee tebe Neg exe 11 5 1 Site Selection eret teen Ea a d Rune solving P Pd ev E Soa nah re dta iat adde 11 5 2 Rear Panel Connections And Rotating Drive Assembly 12 5 3 14 Pin Plug PLG12 Information a 13 5 4 Gun Recommendation Table 13 5 5 Wir
14. 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 VA y 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 If using lift forks to move unit be sure forks are long enough to extend beyond opposite
15. 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 going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som 3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s Symbole graphique d avertissement Attention Cette pro A c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints Indi
16. 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 A 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 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 A 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 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 223 605 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ins com Principal
17. 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 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
18. ficient cate ANE KRNU RA rer T uu one D mn een DNE Bee eae 26 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 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 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
19. holder 180 degrees and reinstall Install intermediate guide into guide holder with o ring towards rear of feeder Loosen set screw insert exit guide into block near brass power pin gun connection and secure with set Screw I When using smaller diameter inlet guide 219108 with non PD old style drive rolls a 1 4 in 6 mm gap will be present between the guide and drive Tools Needed roll 1 16 3 32 in Ref 804 192 804 188 A OM 223 605 Page 15 5 9 Installing Welding Gun R PE Installing gun with Accu Mate connection 2 Power Clamp Knob Gun Locking Tab Power Pin Groove 4 Gun Connection End Installing gun with Accu Mate connection On Loosen power clamp knob to allow power pin of gun to clear the gun locking tab When installing gun the liner should extend into the PD continu ous guide or exit guide if used as far as possible without interfering with the guide Align the groove in the power pin of the gun with the gun locking tab Secure gun by tightening power clamp knob Installing gun without Accu Mate connection When using a gun without the groove in the power pin loosen power clamp knob and rotate gun locking tab 180 degrees This pre vents the locking tab from extend ing into the power pin gun connec tion When installing gun the liner should extend into the PD continu ous guide or exit guide if used as far as po
20. r parer cet appareil S 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 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 seit qi P Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures a se r r js t I kak mi dd s a nt lt graves Le circuit de l lectrode et de la pi ce est dese el que ous GS PANNEAUX El couvercies sont correcementen sous tension lorsque le courant est d livr la place n 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 pa
21. 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 se STATIC ESD can damage PC boards 7 e Puton grounded wrist strap BEFORE handling ASS boards or parts s e Use proper static proof bags and boxes to store move or ship PC boards K 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 1 4 California Proposition 65 Warnings 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 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
22. 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 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
23. 9 n 9A0019 A epino epiny epino epin5 IIOH apiny lloH OUJON uonoel4 wag l eIp uui lul Jeu snounuog 9oAug snounuoo 9AHG dd dd dd Od pounbei v pounbes yore I sog eias PIO pounbes opin6 L 9 SIO1 t 40 151 L pounbei opin6 L 3 SjlO4 t 10 14 L ZIS M SIIOH SAG prepueis unujun y 40 Gd ALMA PACH 10 Gd S PINH pue siloti SAG 9I 1S pIO pue eAuq uoisi29Jg Qd L 6 eigen OM 223 605 Page 32 Notes H OF WELDING TECHNOLOGY Start Your Professional trade square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in 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 C
24. EM soy 27 lt lt prez ESL IM cok vage dH EM uu lt RC6 2 1 lt H s lt 14 lt Zw gt 14 gt e lt Rce 1 i st x P Sh S S a a O gee 5 z ZAME 5 gt Z lt Rc4 2 GS1 JE JG 76 lt 1 lt 4 M 54 gt lt RC4 1 g PUR 9 Ak lt MT se 6 lt gt 5 gt lt lt RC4 4 S 75 74 amp STANDARD 75 LOW SPEED SPEED 77 77 KEP lt E c 3 ere E SO lt RC4 3 Q le re NM 6E RED e YEL ES a 3 3 3 RC5 3 W METERS 8 lt 3 lt lt 3 lt gt gt lt lt OR WHEN USED gt LIGA lt 2 pe lt BE gt p gt lt RC5 2 2 WHT WHT lt 1 lt Z c lt ON ay 70 D Rest HF STUD O K RCI5 14 PIN PLG12 S1 lt LAK A ONCE RI 6 lt PURPLE 2 ZAVAC COM RGI B lt FLED CONTACTOR RC3 5 r YELLOW CURRENT FEEDBACK nos H lt BROWN VOLTAGE FEEDBACK lt lt RC3 6 c lt PINK AS 410 lt lt RO3 2 p ZE PS COMMAND ees a D lt ORANGE PS COM ROZ Z PC1 MOTOR BOARD RC1 PLG1 RC3 PLG3 RC4 PLG4 RC5 RC6 PLG6 RC7 RC9 PLGS RC10 PLG10 RC11 TRIG HOLD 6 RC8 2 gt gt RCB 1 gt IIV Z Joc 12 RC10 5 l TRIGGER s HOLD RC10 1 gt gt 244 I po sz J00 Re10 a sS E F LAV 5 PURGE RC9 1 gt gt 0 70 75V JO RC9 3 gt gt COM 70 R RC9 2 gt gt 8 Do not touch live electrical parts Disconnect input power or stop 4 WARNING engine before servicing Do not opera
25. Flathd Soc Stl Pin 0 1 EE cA EE 223 252 Tachometer Optical Encoder 0 1 OM 223 605 Page 31 eJIM GO BSN O UNB eui ueAuoo oj sdn 39e u00 st0 sepnjoul UNB o00rO eur IM 104 eAup Ad SVO epnjour osje G7 S SSL S 8u L 8JIM GEO 10 dn jes un goro e pue pejeisur sepinb sijoy 8AUP Gd SEO UNA Moose eu OY peddius eie qS S 9 SS S eu cIZEG0 96cE L ZOZESO 8ISEcc 9ISECC 601612 Lt LLZESO c96CE SOZESO 8LSEZZ 9LSEZZ 601612 ut v9 7 60ZESO L96c L gozeso 8lseca 9ISECC 60L6LZ 760 ut ZE E OLZESO 096261 0 650 818622 9ISezz 601612 nu 6S6ZEL LISecc SIGEcC 80L6LZ 860822 Loszaz 848vcc U 270 890 z90 gozeso SS62 L 90Z S0 669 S0 LISEcC SISEcC 801612 LOLEZZ 00Gccc Lr0008 860822 00Gccc LL8be0 ul OL L 06 80 9G6CE L cO0 G0 869 G0 LLGe2c SIGecc 80L6LZ LOLEZZ 66v2cc 460 2c 66vccc 928vcc uu y L EL ut GO 68v 80 2866 Lozeso Z69 S0 LiSecc SIGECC 80161c 001 cc 86vccc Ov 000 Z60ezz 986vccc S 8vcc uulzi pi MZv0 SvO LISecc SIGEcC 80L6LZ 00L cc L6vece Z26084 L6vccc v28vcc WwW OL Ul OvO 8S6ZEL 000240 00zeso LiSezz giGezz 801612 660822 96vzz2 6 000 geoezz 96vzzz L8b7z uiu 60 Ul GEO S69 S0 LiSecc SIGEcC 801612 660caz Sevcez 8 000 960 CC S6vccc cL8vce ww 80 Ul 0 0 0 1280 LISEcc GLSEZZ 801612 960 cc vevozz Lzevoc ww 90 Ul S20 20 9A0045 ON 900014 MA 81001
26. 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 souder DC e 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 ventile ou en est recom
27. Or FC 1150 5 5 Wire Type Size And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard All 023 To 5 64 in 0 6 To 2 mm 50 To 1400 ipm 1 3 To 35 6 mpm Low All 023 To 1 8 in 0 6 To 3 2 mm 20 To 400 ipm 0 5 To 10 1 mpm 5 6 Installing Drive Rolls K 1 Pressure Assembly Door 2 Drive Roll 3 Ejector Button 4 Drive Roll Carrier Installation Open pressure assembly door Align drive roll slots with three lobes on drive roll carrier Insert drive roll onto carrier Drive roll will snap into place Removal Must remove PD wire guide be fore removing lower drive rolls Lift up drive roll swing arm and press ejector button in middle of drive roll carrier i If ejector button does not re turn to normal position out install a drive roll and ejector button will pop out 804 187 A OM 223 605 Page 13 5 7 Installing PD Continuous Wire Guides 47 PD Continuos Wire Guides Should be used with 068 072 in 1 8 mm and smaller diameter wire for opti mal performance Should be used with PD drive rolls and cannot be used with non PD old style drive rolls 70 series wire guides are not compatible with 75 series wire feeders Pressure Assembly Door PD Inlet Guide PD Wire Guide Hard Wire PD Wire Guide Two Pieces interlocked for Aluminum Wire Ins
28. a 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 223 605 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 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 su
29. cs 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 Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les 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
30. d 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 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
31. e Power Consisting Of 1 1 ex eee 163 519 22 3 Caley Port cout Te Peden ette eee ede ee 11 5 Ft 3 5 m za Owing tn bane tx aie ed oe 139041 Strain Relief Nadie PEDES 079 739 Conn Circ Cpe Clamp Str Rif Taxis 10 PLG12 141162 Housing Plug Pins Service Kit Tes xn etes PLG3 115093 Housing Plug Skts Service Kit 1 1 eed e 200 554 Enclosure Motor 1 1 d up RON 220 805 Nut 750 14 Nps 1 48Hex 41H Nyl Jesus 21 13 GS1 219062 Valve Gas W Fittings 34VDC lise RE ee stesse DE 134 201 Stand Off Support Pc Card 6 6 se dip ua e ed 200551 Enclosure Control Tian 16 ST aui 111 997 Switch Rocker Spst 10a 250 Vac On Off T cec hist POL xo 224 307 Circuit Card Assy Motor Control W Program Tas A Agile 92 112 200 295 Switch Rocker Spdt 15a 12v On Of On Toe ka LD iius SI iaa 201 642 Switch Rocker Spdt 15a 12v On None On d rias xus s ERES 223 603 Nameplate Lower 1 OM 223 605 Page 28 Quantity Item Diagram Part Model N
32. e but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 1 05 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip n n For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2005 Miller Electric Mfg Co 1 05 Miller Electric M
33. e Type Size And Feed Speed Capability Table 13 5 6 Installing Drive ROMS 2 55 u Tu ani oja S RII dun K EN ete UBRO Lt eee EM utu ha gee alec 13 5 7 Installing PD Continuous Wire Guides 14 5 8 Installing Non PD Old Style Wire Guides 15 5 9 Installing Welding Gun IIR I hr 16 5 10 Installing Welding Wire And Adjusting Pressure Drive Setting 17 5 11 Setting Internal DIP Switches 18 5 12 Equipment DIP Switch Settings For Models With Meters Only 19 SECTION 6 OPERATION I a re ELA ERU aie Msn eme anus coins 20 6 1 PowWer Switch si nisi nani ka EEA ena e d eoe RR AE DELE AE LE NE Areas puq 20 6 2 Jog Purge And Trigger Hold LLLL a 20 6 3 Voltage Control And Digital Meters For Models With Meters Only 21 SECTION 7 MAINTENANCE sis 50000 nn omega ee Dame Rese eigen sia Lidije 21 7 1 Routine Maintenance Haies ae ERIMM NP DERE Y e Aas M a darse ens 21 752 DIAGNOSTICS stereo eei belt e Ne et ing Mae wade e au ue ej e aon ace Pe E 22 7 3 Tro bleshooting u ak tends eie EX Bei e Ese IRR EDEN Der ej UID uS EUR E 23 SECTION 8 ELECTRICAL DIAGRAM ssssee III III nnn 24 SECTION 9 PARTS LIST
34. e 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 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 EIC FLYING METAL can injure eyes e Weld
35. es 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 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
36. fg 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
37. function place the trigger hold switch in the On position e The operator must hold the trig ger for a minimum of 2 seconds but not longer than 6 seconds be fore releasing it Welding will con tinue when the trigger is released e To stop welding press the trigger again 3 Wire Speed Control 4 Gun Trigger Receptacle 802 828 A OM 223 605 Page 20 6 3 Voltage Control And Digital Meters For Models With Meters Only 1 Voltmeter The voltmeter displays actual or preset voltage from the welding power source through the 14 pin control cable 2 Wire Speed Meter The wire speed meter is factory set to display inches per minute If dis play of meters per minute is de sired see Section 5 12 3 Voltage Control Use control to adjust voltage output of welding power source I You can adjust the preset volt age display on the wire feeder to match your power source s display by adjusting P2 on mo tor control board PC1 See Section 7 2 for location of P2 804 182 A SECTION 7 MAINTENANCE 7T 1 Routine Maintenance Disconnect power before maintaining Repair or O38 6 Months Blow out or vacuum inside During heavy service clean monthly Clean drive rolls WARNIN A Clean and 2 Replace Ee tighten replace i unreadable y Em weld acked D labels terminals 3 weld cable Replace Chec
38. hose with 5 8 18 right hand threads Shielding gas pressure not to exceed 90 PSI 620 kPa 3 Weld Cable 4 Weld Cable Screw Screw Size 375 16 X 1 50 4 Note two weld cable connec tions 0 to 350 Amps and 350 Amps and above 5 Drive Assembly 6 Drive Assembly Rotation Knob To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob 7 Rating Label Location 350 Amps and above weld connection 0 to 350 Amps weld connection Tools Needed 3 t 9 16 in Ref 804 183 A 804 184 A OM 223 605 Page 12 5 3 14 Pin Plug PLG12 Information Z REMOTE 3 4 Pin Pin Information A 24 volts ac with respect to socket G B Contact closure to A completes 24 volts ac contactor control circuit G Circuit common for 24 volts ac circuit C 10 volts dc input from power source to wire feeder with respect to socket D D Remote control circuit common E 0 to 10 volts dc output signal from wire feeder to power source with respect to socket D H Voltage feedback 0 to 10 volts dc 1 volt per 10 arc volts F Current feedback 0 to 10 volts dc 1 volt per 100 amperes The remaining pins are not used 5 4 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires Q Series Guns 300 400 500 And 600 Amp FCAW Self Shielding Wires FC 1260
39. ing 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 223 605 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 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
40. ion between e the motor and the meter board if equipped The user may continue to weld with this er ror The error may be cleared by turning power Off waiting a minimum of two sec onds and turning power On The trigger error occurs if the user has the trigger held for more than two minutes with out striking an arc providing current over ride is not enabled or if the user holds the Ref 802 687 trigger past the postflow phase in a timed weld This error also occurs if the trigger is held when the feeder is powered up The er ror may be cleared by releasing the trigger The tach error occurs 2 seconds after the loss of tachometer feedback The user may continue to weld with this error The motor speed is regulated through the monitoring of voltage and current The motor error indicates that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle OM 223 605 Page 22 7 3 Troubleshooting Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but Check cable connections Check cables for continuity and repair or replace cables if necessary electrode wire is not energized see Section 5 2 Wire feeder is on display does not light Check and reset circuit breaker at welding power source up motor does not run gas valve and welding power source contactor do not pul
41. k Check gas cracked 14 pin cord hoseand 4 PD gun parts fittings 2 OM 223 605 Page 21 7 2 Diagnostics NN wg gt would be in place Wrapper Motor Control Board PC1 LED3 P2 n Front panel is shown removed for purpose of illustration only In actual use front panel Display On Meter If Equipped LED3 Sequence On Motor Control Board PC1 Indicated Error HELP 11 1 Blink Communication Error HELP 12 2 Blinks Trigger Error HELP 13 3 Blinks Tach Error HELP 14 4 Blinks Motor Error Since blink On time and blink Off time are equal in a four blink cycle the four blink sequence appears as constant blinking e Error Indications Error conditions are indicated by LED3 on PC1 or on display on models with meters To view LEDS turn Off unit remove wrapper and turn unit On LED3 is most easily observed from the left side of the unit The LED blinks in a 2 5 second cycle The number of blinks in this period indicates the type of error The priority of the errors is related to the num ber of blinks indicating the error The more blinks the more severe the error motor error is top priority A higher priority error overrides a lower one if a motor error and a communica tion error existed the light would blink four times for the motor error e The communication error occurs 2 5 sec onds after a loss of communicat
42. l in Electrode wire feeding stops or feeds Check gun trigger connection See gun Owner s Manual erratically during welding Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 5 10 Change to correct size drive roll see Section 5 6 and Table 9 1 Clean or replace dirty or worn drive roll Incorrect size or worn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around nozzle opening Have Factory Authorized Service Agency check drive motor or motor control board PC1 Motor runs slowly Check for correct input voltage Wire feeder power is on displays light Check welding gun trigger leads for continuity and repair leads or replace gun up feeder jogs purges but unit is in operative When triggered wire feeds but no gas If the welding arc does not establish in 3 seconds after the gun trigger is activated the unit will feed no contactor wire but turns off contactor and gas valve If the gun trigger is still activated after two minutes the wire will stop feeding OM 223 605 Page 23 SECTION 8 ELECTRICAL DIAGRAM DETACHMENT OPTION OR WHEN USED AS SWINGARC RECEPTACLE e s 8o dE 4 gt 2 ae g lt gt gt ZE lt lt noe 4 gt 2L GRN coe T Leto H
43. lankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipmentthat has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credi
44. mand 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 gralssage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute ZA a 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 l
45. meter P1 located on Motor position be in either position speed Board PC1 IF If 14 pin power cable from pow er source does not provide volt age and current feedback Run In will automatically disable 803 063 Ref 802 944 OM 223 605 Page 18 5 12 Equipment DIP Switch Settings For Models With Meters Only Remove wrapper Install wrapper when finished Digital Meter DIP Switch Setting Factory Default Inches Minute Factory Default Meters Minute 5 4 l re i lo w Tools Needed EE E 1 4in Ref 802 946 OM 223 605 Page 19 SECTION 6 OPERATION 6 1 Power Switch 1 Power Switch 804 182 A 6 2 Jog Purge And Trigger Hold 1 Jog Purge Push Button Pressing the Jog Purge switch al lows the operator to jog wire without energizing the weld power or gas valve circuit e Jog speed can be adjusted with the Wire Speed control when the unit is jogging wire If equipped with meters the unit displays jog speed while the unit is being jogged Pressing the Jog Purge button also allows the operator to purge gas lines before welding and to preset gas pressure at the regu lator 2 Trigger Hold Switch Trigger hold allows the operator to weld without holding the gun trigger To use the trigger hold
46. o marking No Description S 75S S 75D Figure 9 2 Control Box Figure 9 1 Item 21 Dal cens 213 134 Knob Encoder 1 670 Dia X 250 Id Push On W Spring 0 1 PARODY bM dak taki 119951 Blank Snap in Nyl 437 Mtg Hole Black 1 0 sae QO PR RS onsite 171007 Knob Pointer 1 670 Dia X 250 Id W Set Screwsplstc 1 0 ny QO ae Z Sac eee 213 134 Knob Encoder 1 670 Dia X 250 Id Push On W Spring 0 1 eese d versa ier is 223 604 Nameplate Upper 1 0 seats OE NI 203 214 Nameplate Upper W Meters Os Sas PA a Mowe ches went 223 603 Nameplate Lower tsa as 1 MAD ire uuu ann ose 202 237 Panel Front lisant antenne uu Rie C del aan ar ae T uud 26 RC13 048 282 Rept W Skts Service Kit usa E PLG8 131054 Housing Rcpt Skts Service Kit 1 1 iue irem PLG9 201665 Housing Plug Skts Service Kit 1 1 der RES PLG6 115094 Housing Plug Skts Service Kit 1 1 nod sad te PLG1 202592 Housing Plug Pins Skts Service Kit 1 1 a tenes PLG4 136810 Housing Plug Pins Skts Service Kit 1 1 T PLG10 130203 Housing Plug Skts Service Kit
47. o 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 223 605 Page 9 3 2 Symbols And Definitions Note gt Some symbols are found only on CE products A Amperes V Volts CN Alternating Current X Duty Cycle Dp Mic mk H Z Hertz gt Program olo Wire Feed 7 Jog e Output 6 lt Trigger d Line Connection lt gt Set Up Sequence se Trigger Hold On e Trigger Hold Off 4 Purge k Press To Set Start Crater t Time ti Preflow Time 4 t2 Postflow Time b Read Instructions C Increase l 1 Primary Current L Rated Current U 2 Load Voltage U 1 Primary Voltage gt Dual Schedule Notes OM 223 605 Page 10 SECTION 4 INTRODUCTION
48. ode 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 To reduce magnetic fields in the workplace use the following procedures OM 223 605 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
49. onductive Ref 804 190 A Tools Needed COP 15 16 in surface and press gun trigger to feed wire against surface Adjust pressure drive lever so wire does not slip Do not overtighten If contact tip is completely blocked wire should slip at the feeder see pressure adjustment above Cut wire off OM 223 605 Page 17 5 11 Setting Internal DIP Switches Remove wrapper 1 DIP Switch S1 On Motor Board PC1 S1 1 Run In enable or disable S1 2 Automatic Run In versus Manual Adjustment Run in Install wrapper when finished NS This illustration shows 8 S si the factory setting of S1 1 gt In the DIP switch S1 illustrations the elevated slider on each switch is shown in white For example the switches above are in the Off position Tools Needed CFO 14 in Position Settings And Results For DIP Switch S1 On PC1 Run In Enabled Run In Disabled Automatic Run In Manually Adjusted Run In Factory Default Factory Default r Ww I N CE N N C Ep un s ka S1 1 S1 1 S1 1 And S1 2 S1 1 And S1 2 Run In feature is available Run In feature is not avail Run In speed is approxi Run In speed is set using poten X Means switch may be in either able X Means switch may mately 1 2 weld wire feed tio
50. onic equipment e Be sure this welding machine is installed and grounded according to this manual e If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 223 605 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global 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 C
51. ontact 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 other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American di
52. or 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 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 catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ts Symbol Usage stor qe ER ERA n e POUR nea eae ea 1 122 Arc Welding Hazards tette Pre ups e d puce c ISSUE USE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 4 1 6 EME Inforrmalion siente a mn rm pial ese Fuld ER OE alls net a a Saale x ee oe PE 4 SECTION 2
53. que un message de s curit particulier Ce groupe de symboles signifie Avertissement Attention Risques q 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 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 matiere de securite 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 completes fournies ou mal piss s gans les normes oe piii de secite dans la Section 2 5 Lire et amp Ne pas enrouler les c bles autour du corps e USA Pa 3 e Sila pi ce soud e doit tre mise la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et
54. r 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 e 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 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 gneusementavec
55. 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 223 605 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 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 th
56. roniques 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 cables 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 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
57. rties m talliques en contact 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 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 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 II 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
58. ssible without interfering with the guide Secure gun by tightening power clamp knob Installing gun without Accu Mate connection 804 189 A OM 223 605 Page 16 5 10 Installing Welding Wire And Adjusting Pressure Drive Setting CP CE Pressure assembly Drive Rolls door not shown Install wire spool Adjust tension nut so wire is taut when wire feed stops Adjust tension Back Of Gun Thread wire sort WIRE End Of Liner No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever Indicates Pressure Settings Pressure drive settings range from 1 to 9 with 9 being the maximum setting 47 For aluminum soft wire set pressure drive setting at 4 or below Be sure that gun has proper size liner for the welding wire size When installing gun the liner should extend into the PD continuous guide or exit guide if used as far as possible without interfering with the guide Install gun Lay gun cable out straight Cut off end of wire Push wire through guide up to drive rolls continue to hold wire Press Jog button to feed wire out gun To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonc
59. stributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated 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 B
60. t for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be availabl
61. talling PD continuous wire guides with PD drive rolls Q N 7 Identified by initials PD and a part number on drive roll Open pressure assembly door Lift up drive roll swing arms Remove PD inlet guide Insert wire guide gun end indi cated with arrow into block near brass power pin gun connector 4 When installing two piece plas tic PD continuous guide for use with aluminum wire make sure the two grooves in the guide are aligned Install PD inlet guide IF Do not tighten set screw to se cure inlet guide 7 Set screw may be used to se cure PD inlet guide replace ments such as wire straighten ers or conduit adapters Ref 804 192 804 188 A OM 223 605 Page 14 5 8 4 Installing wire guides with non zu X Eo PD old style drive rolls IF Non PD old style wire guides and drive rolls should be used with 5 64 in 2 0 mm and larger diameter wire Pressure Assembly Door PD Inlet Guide Intermediate Guide Guide Holder Exit Guide Open pressure assembly door Q N Lift up drive roll swing arms Install PD inlet guide 4 Do not tighten set screw to se cure inlet guide 7 Set screw may be used to se cure PD inlet guide replace ments such as wire straighten ers or conduit adapters Remove screw securing intermedi ate guide holder guide holder is lo cated between the lower front and rear drive roll carriers Rotate guide
62. te with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD DORAD W METERS A RG11 1 2411 RC11 2 gt 2 22 lt RC61 1 74 cov lt lt RC61 2 70 RC11 5 gt 5 PLG11 FIV lt lt RC61 5 JS RC7 9 gt 9 gt RC7 10 gt 10 gt lt lt RCB7 9 70 PLG7 lt lt RCB7 10 PC6D METER BOARD RC61 PLG61 RC67 PLG27 RC7 5 5 COM 5 FIV JI 10 lt 1 PLG17 RC7 8 A 8 RC7 2 gt 2 gt 2 PLG17 ES 7 0V JJ RC7 1 gt 1 gt P COMMAND 57 z o W METERS RC7 3 gt 3 PS COM 54 QR REMOTE VOLTAGE OPTION y R70 PLG7 202 246 B ircuit Diagram Figure 8 1 C OM 223 605 Page 24 Notes OM 223 605 Page 25 SECTION 9 PARTS LIST F gt Hardware is common and not available unless listed Fig 9 3 9 4 804 185 A Figure 9 1 Main Assembly OM 223 605 Page 26 Item Part No No Description Quantity Figure 9 1 Main Assembly z oae ves d 159 647 Insulator Motor Clamp 1 Tu DUE 159 646 Clamp Motor Base 1 PP s PET UT ET 159360 Insulator Screw Machine
63. u a 1 jio MEM eer 219096 Knob Tri Lobe W 375 16 Stud 2 500 LgBik 1 20 i cerca woe 219125 Screw 010 32x 50 Soc Hd Hex PIN 1 2 eua a m Pas 219091 Holder Guide Intermediate 1 PA ais We 219 129 Screw 010 32x1 50 Soc Hd Hex Stl PId 2 performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 5 Hardware is common and not available unless listed 1 804 191 A Figure 9 4 Drive Assembly With Motor Quantity Item Diagram Part Model No marking No Description S 75S S 75D Figure 9 4 Drive Assembly Wire Figure 9 1 Item 4 d hair bot 079 626 Screw 010 32x 87 Fil Hd Phl Stl Pld Lkg Patch 4 4 vi ang dA Figure 9 3 Drive Assembly Wire 1 1 SUS mate uns M1 219088 Motor Low Speed Poni NRC eee M2 219087 Motor Gear 09HP 24VDC 273RPM 29 1 Ratio ah cea Standard Speed 1 1 Paci AP uci ee hee ete 223 253 Adapter Optical Encoder Standard Motor 0 1 nur guetta Beebe dt 223 254 Adapter Optical Encoder Low Speed Motor Ores iin 1 TD 219 103 Screw 010 32x 75
64. welding wire are electrically live Incorrectly installed or improperly grounded eguipment 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 reguired for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are reguired when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eguipment 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 groun

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