Miller Electric R-115 User's Manual
Contents
1. 13 3 9 Interconnecting Power Cord Ground Lead Connection All Models 14 3 10 Connection For L TEC Welding Power Sources With 7 Flat Socket Receptacle 14 3 11 Connection For Hobart Welding Power Sources With 19 Socket Receptacle 15 3 12 Connection For L TEC Welding Power Sources With 19 Socket Receptacle 15 3 13 Connection For Hobart Welding Power Sources With 5 Socket And 115 Volt AC Receptacles 16 3 14 Connection For Lincoln Welding Power Sources With 14 Socket Receptacle 16 3 15 Connection For Lincoln Welding Power Sources With Terminal Strip Connections 17 3 16 Connection For AIRCO Welding Power Sources With Two Prong Twistlock And 115 Volts AC Receptacles hed dn ee re oh IMMER GMAT wane ae 17 3 17 Connection For Welding Power Sources With Hubbell Receptacles 18 3 18 Connection For Miller Welding Power Sources With 14 Socket Receptacle 18 3 19 Motor Start Burnback Control 19 SECTION 4 OPERATION iid cary sue er Nahe 20 4 1 Eront Panel Controls tt an EY 20 4 2 Optional Side Panel 5 20 SECTION 5 MAINTENA2. 22 Mi 193 188 MOTOR gear 24VDC 146RPM consisting of TERT 136 745 BRUSH amp SPRING ASSEMBLY S29 ss 073 562 POTENTIOMETER C sitd sft1 T 2W ohm 24 S2 211 476 SWITCH tgl SPTT 6A 125VAC 25 PAS WE 134847 SWITCH tgl SPDT 15A 125VAC CS E 189 404 SPACER nylon OD use ed usc 194 401 LABEL warning ground current sel ona 197328 CASE ASSY are as p p Dern Rd Ee RF PO perpe ed NAMEPLATE order by model and serial number nw RC2 191 239 CONNECTOR w leads 2097 elatus add 097 924 KNOB pointer on LS 048 282 CONNECTOR amp SOCKETS Solar 196 956 LABEL warning electric shock and 192 875 INSULATOR drive motor O Fig 6 2 WIRE DRIVE ASSEMBLY trad out 188 149 GUIDE wire inlet 030 thru 5 64 in dia consisting of agar Mord dar de Moe 082 050 LINER monocoil i
3. 1 r p E 057 971 WASHER flat stl keyed 1 500dia 125thk 1 p ERE 010 191 WASHER fbr 656 ID x 1 500 OD 1251 2 ted Oris Doa tours das 058 628 WASHER brake stl 2 sto T st hus 058428 HUB Den Re dea d et 1 fret 135 205 NUT stl sfflkg hex reg 625 11 w nylon insert 1 Gg eran is ek ak 134306 FOOT rbr 1 250dia x 1 875 high 4 187461 BASE exis mae uU CHINESE grag aA 1 vias 193 351 TRANSFORMER control 115 24VAC 1 111997 SWITCH rocker SPST 10 250VAC 1 17 CB1 011 244 CIRCUIT BREAKER man reset 1P 2A 250VAC 1 193 471 24 Item Dia Par Mkgs No Description Quantity Figure 7 1 Main Assembly Continued PNB D eens 044 426 CONNECTOR clamp cable 19 G81 228036 VALVE 24VAC 1way 750 14 thd 2mm orf 100PSI 20 193 440 SWITCH ground current Sensor 21 end Tess 193 376 BLOCK terminal 20A 5 UD 193 500 LABEL terminal mkg 20A 5 pole
4. 193 471 2006 05 E Miler MIG GMAW Welding Flux Cored FCAW Welding Description EIER Wire Feeder OWNER S MANUAL File MIG GMAW m 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 Bl 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 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 90 00012000 of reliable service with proper maintenance And if for some reason the un
5. ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots 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 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 193 471 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global 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
6. 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 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 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 Lecouvercle du d tendeur doit toujours tre en place sauf lors qu
7. 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 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
8. 1 2 in 030 To 3 32 in 597 115 Volts AC Single Phase erde o 106792 500 Amperes Width 10 3 4 in AGRO 2 re 50 60 Contactor Control 19 10 19 mpm Spool Weight Duty Cycle 273 60 Ib 27 kg Height 11 in 279 mm 3 2 Site Selection Wire Feeder 1 2 Lifting Eye 3 Rubber Feet 4 Slot Choose slot that allows all rubber feetto sit securely on top of welding power source 5 Wire Spool Reel 6 Gas Cylinder Customer Supplied Shielding gas pressure not to exceed 100 PSI 689 kPa 7 Welding Power Source Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip 802 304 A 155 242 OM 193 471 Page 9 3 3 Gun Recommendation Table Process Gun GMAW Hard or Corded Wires M25 Or M40 FCAW Self Shielding Wires GA 40GL 3 4 Equipment Connection Diagrams 1 CV Welding Power Source With 115 VAC Power 2 Interconnecting Control Cord Required 3 Weld Cable Required 4 Work 3 5 Rear Panel Connections And Power Switch Location 1 Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied Shielding gas pressure not to exceed 100 PSI 689 kPa 2 Strain Relief Install interconnecting cord to make connection to welding power Source see Section 3 9 3 Power S
9. 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedu
10. Receptacles Re JN Qe Tools Needed E C H 1 4 in Make ground lead connections according to Section 3 9 before following this procedure Terminal Block 1 3 Conductor Cord 2 Conductor Cord Green Lead Connected To Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection Pop D Dry Contact Closure w Respect To Terminal E Lead E 115 VAC Contact Closure Lead gt For welding power sources requiring dry contact closure move lead 38 at terminal block to terminal Secure strain relief clamp around cords Reinstall and secure wrapper to unit Connect remaining cord ends to welding power source Ref 802 310 Ref 193 749 3 14 Connection For Lincoln Welding Power Sources With 14 Socket Receptacle Tools Needed EL 1 4 in Make ground lead connections according to Section 3 9 before following this procedure 1 Terminal Block 1T 2 Interconnecting Power Cord 3 Green Lead Connected To Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection D Dry Contact Closure w Respect To Terminal E Lead E 115 VAC Contact Closure Lead gt For welding power sources requiring dry contact closure move lead 38 at terminal block to terminal D Secure str
11. Tone PC70 210 408 CIRCUIT CARD ASSY control IP PER TER EBEN TER 194 310 BRACKET mounting pidas Eee e isis 097 132 STAND OFF 6 32 375 10 250 hex 4 093 5512 22 KNOB occ IAE EU ead Eres A E 4140789 SWITCH RECON PX e 210 436 LABEL indicator run in OMIM 193 719 BRACKET mounting receptacle n dat a suu d 115 093 HOUSING PLUG amp SOCKETS 131 059 HOUSING PLUG 8 SOCKETS 115091 HOUSING PLUG amp SOCKETS E 135 531 HOUSING PLUG amp SOCKETS BON TEN HEINE RER 048 282 HOUSING PLUG 8 SOCKETS 211 989 FITTING w screen BL JOUE 194308 LABEL miller 8 250 x 3 500 horizontal blk wht When ordering a component originally displaying a precautionary label the label should also be ordered OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested R
12. damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and
13. gt 3 COMMON 15 4 xq 3 xE 5 35voC TO MOTOR CONTROL 2 gt gt 2 BOARO ARE 45 CONNECT TO sce 5 5 INTO RC4 a ae 1 gt 7 4 gt 4 5 5 43 lt lt RC79 4 0 lt lt 5 ES PC70 REED SWITCH u NOTE ROUTE WELD CABLE 12 5 lt lt nc76 5 OPTIONAL O THROUGH REED IT gt RC79 PLG79 SWITCH ASSEMBLY 4 gt lt lt RC76 6 RC76 PLG76 RC70 PLG70 193 378 C t ipmen Equ lona Feeder With Opti Ire For W ircuit Diagram Figure 6 1 C OM 193 471 Page 23 SECTION 7 PARTS LIST Hardware is common not available unless listed 802 305 D Figure 7 1 Main Assembly Item Dia Part No Mkgs No Description Quantity Figure 7 1 Main Assembly laine 089899 Lisa ethnies Na EI GA S 1 198 651 2 WRAPPER 5i Ausser uet rex E RE geld 1 por Mean 120 873 BOMPER nr Herne pl SRE daa 134 464 LABEL warning electric shock 1 Uis rats en 072 094 HUB amp SPINDLE ASSEMBLY consisting 1 058 427 RING retaining spool 1 PEE e n eee 180 572 SHAFT spool 1 tae 010233 SPRING cprsn 970 OD x 120 wire x 1 250
14. 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 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 gt 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 amp 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 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire E 3 1 4 California Proposition 65 Warnings 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 Secti
15. or equipment manufacturer s Transportation Department PRINTED IN USA 2006 Miller Electric Mfg Co 2006 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com 2 Miller
16. 500 1 MEDD exe en 187325 INSULATOR drive assembly 1 EE ES 144172 FITTING hose brs barbed m 3 16 tbg 250 20 1 ES 166 337 HOUSING adapter gun feeder 1 Bred rn 072010 WASHER shldr 316 ID x 812 OD x 187thk 2 m E 168 590 BUSHING insulating 1 2 PEE O E 124778 KNOB T 2 000 bar w 312 18 1 00019 1 OV E seyn 079 625 WASHER wave 500 ID x 750 OD x 015thk 2 E t T ta 092 865 x IKEYZSU tte tbe px Ave Aude od 1 AC NE EM 172 077 CARRIER drive roll keyed 24 1 BEI arcsec et see 121271 SCREW 250 20 x 500 soc hd 1 Hardware is common and See Table 7 1 For Drive not available unless listed Roll amp Wire Guide Kits 802 307 A Figure 7 2 Drive Assembly Wire 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 193 471 Page 26 Table 7 1 Drive Roll amp Wire Guide Kits NOTE F Base selection of drive rolls upon the following recommended usa
17. NCE amp TROUBLESHOOTING 21 515 Routine Maintenance detre Be pubs POS RU PUR PER idad 21 5 2 Overload Protection ut tke a e ERR RE PRU Ra RUE PER E e eee OR ee ala 21 553 Troubleshooting cia iets rore o nene aeree Pea pie dae E pa aa 22 SECTION 6 ELECTRICAL DIAGRAM z ie E m e RR Rex 23 SECTION 7 PARTS LIST iR RIA EE ee rer ERR esee 24 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 4 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 ope
18. VAC Hot Lead C No Connection D No Connection E 115 VAC Contact Closure Lead Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Tools Needed N CAPO 1 4 in Ref 802 310 Ref 193 749 OM 193 471 Page 17 3 17 Connection For Welding Power Sources With Hubbell Receptacles Make ground lead connections according to Section 3 9 before following this procedure Tools Needed C k 1 4 in 1 Terminal Block 1T 2 Interconnecting Power Cord 3 Green Lead Connected To Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection D No Connection E 115 VAC Contact Closure Lead Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Ref 802 310 Ref 193 749 3 18 Connection For Miller Welding Power Sources With 14 Socket Receptacle Make ground lead connections Tools Needed C r ud 1 4 in according to Section 3 9 before following this procedure Terminal Block 1T Interconnecting Power Cord White Lead Black Lead Red Lead Green Lead Connected To Ground In Section 3 9 Connect remaining leads to terminal block as follows A White Lead 115 VAC Neutral B B
19. ain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Ref 802 310 Ref 193 749 OM 193 471 Page 16 3 15 Connection For Lincoln Welding Power Sources With Terminal Strip Connections 1 Terminal Block 1T x Make ground lead connections according to Section 3 9 before 2 interconnecting Power Cord following this procedure 3 Green Lead Connected To Ground In Section 3 9 Connect remaining leads to terminal block as follows 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection D Dry Contact Closure w Respect To Terminal E Lead 115 VAC Contact Closure Lead x For welding power sources requiring dry contact closure move lead 38 at terminal block to terminal D Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source GND Tools Needed 2 Red 4 Orange 31 White 32 Black CF 1 4 in Ref 802 310 Ref 193 749 3 16 Connection For AIRCO Welding Power Sources With Two Prong Twistlock And 115 Volts AC Receptacles Make ground lead connections 1 terminal Plock IT according to Section 3 9 before 2 Interconnecting Power Cord following this procedure 3 Green Lead Connected To Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115
20. 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 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes
21. 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 193 471 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 telephone 800 463 6727 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 a
22. ctive it CAF 1 4 in Ref 802 310 192 653 OM 193 471 Page 19 SECTION 4 OPERATION 4 1 Front Panel Controls R 115 115V Wire Feeder MADE IN B Nf N were a O TRIGGER WIRE GE E p A aT TRIGGER HOLD _JONPURGE 75 to 750 IPM 9 2 1 Wire Speed Control 2 Jog Purge Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve Use Purge position to momentarily energize gas valve to purge air from gun or adjust gas regulator 3 Trigger Hold Switch Push up to weld without holding gun trigger throughout the weld cycle To start weld cycle press and release gun trigger within three seconds after an arc has been struck To end weld press and release gun trigger Power switch is on rear panel see Section 3 5 192 510 B 4 2 Optional Side Panel Controls 1 Optional Run In Speed Control The Run In Speed Control provides a means of selecting the rate at which welding wire will feed after preflow and before arc initiation After arc initiation the wire feed speed is governed by the Wire Speed Control Rotating the Run In Speed Control clockwise will increase run in wire feed speed Close side door 2 Reed Relay Switch 3 Weld Cable Weld cable must be routed through reed relay switch present on units with Run In S
23. 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 193 471 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 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 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 Consid rations sur le soudage et les effets de basse fr quence et des
24. e la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil SUR ar nn L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT Pr voir une p riode de refroidissement respecter le cycle op
25. e oe PE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles titiliS6S1 cultam E be 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 win A pa BAT RE SH en E 8 SECTION 3 INSTALLATION x RR 8 20 ended Ha gece eee eee be be Seed 9 351 Specifications ar eps e ORIS dc dhol I Salad RAE 9 3 2 Site Selection sooo obire so AY DTA e I Gave d ied RD ERR 9 3 3 Gun Recommendation 2 10 3 4 Equipment Connection Diagrams 10 3 5 Rear Panel Connections And Power Switch Location 10 3 6 Connecting Welding Gun And Weld 11 3 7 Installing Wire Guide And Drive 12 3 8 Installing And Threading Welding
26. ectrique 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 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 Lire et comprendre
27. elding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 4 Do not install or place unit on over or near combustible surfaces e Do not
28. en 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 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 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 entrainer la mort instructions aff rentes pour viter tout risque Les instructions en L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu
29. enten 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 isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant l
30. eplacement Parts Model and serial number required when ordering parts from your local distributor OM 193 471 Page 25 Item Dia Part No Mkgs No Description Quantity Figure 7 2 Drive Assembly Wire Fig 7 2 Item 1 dua ei ATA 602 009 SCREW 250 20 x 1 250 soc hd hex gr 8 4 du er d E 172 075 CARRIER drive roll w component 24 pitch 4 Ta alah ok ER 166072 5 gt ta Brae 4 Er ceu sevi a 054 263 SCREW thumb stl 250 20 500 2 Amp danced Mes 010224 PIN spring CS 187 1 000 2 de 089 562 FASTENER pinned 2 bs permets 085 244 WASHER cupped stl 328 ID x 812 OD x 125 2 LE rn 089 477 SPRING cprsn 770 OD x 105 wire 1 225 2 Dr pm 085 243 KNOB adjustment tension 2 TE on 166 071 LEVER mtg pressure gear 1 ll M DECENT 079 634 5 hinge ene es Re debere ck ed ttn 1 S Bee fer 151 828 PIN cotter hair 054 x 750 2 v KO AS eas 166 338 LEVER mtg pressure gear 1 Elder 605 308 RING ring ext
31. er in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT 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
32. g wire at contact tip when not in use 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 2 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 193 471 Page 2 a BUILDUP OF GAS can injure or kill 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 Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shi
33. ges 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 Wire Guide PartNo Type Intermediate 046780 053695 056192 056206 046781 053700 056192 056206 191917 053696 056192 056206 046783 053698 056 193 056207 ND 056 206 3 32 132 961 056196 056210 083319 083489 056193 056207 S 0025 D 3 32 046789 053 703 056196 056210 193 471 Page 27 Notes 193 471 Page 28 Notes 193 471 Page 29 Notes OM 193 471 Page 30 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast a
34. ies 90 Days Parts Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers 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 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Mill
35. 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 Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for meta
36. ing to Section 3 9 before following this procedure 1 Terminal Block 1T 2 Interconnecting Power Cord 3 Green Lead Connected Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection D Dry Contact Closure w Respect To Terminal E Lead E 115 VAC Contact Closure Lead Lx For welding power sources requiring dry contact closure move lead 38 at terminal block to terminal D Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Ref 802 310 Ref 193 749 3 12 Connection For L TEC Welding Power Sources With 19 Socket Receptacle EA Tools Needed SS RO 1 4 in Make ground lead connections according to Section 3 9 before following this procedure 1 Terminal Block 1T 2 Interconnecting Power Cord 3 Green Lead Connected Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection D No Connection E 115 VAC Contact Closure Lead Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Ref 802 310 Ref 193 749 OM 193 471 Page 15 3 13 Connection For Hobart Welding Power Sources With 5 Socket And 115 Volt
37. install retaining ring Adjust tension nut so wire is taut when wire feed stops 3 Pressure Assembly Adjustment Knob Lay gun cable out straight A Open pressure assemblies hold wire tightly and cut off end Push wire through guides into gun B Close and tighten pressure assemblies Press JOG button until the wire comes out ofthe gun C To adjust drive roll pressure press gun trigger to feed wire A against wood surface Tighten knob so wire does not slip Cut off wire Close door Tighten A WOOD I Tools Needed IT 15 16in Ref 802 308 S 0627 A OM 193 471 Page 13 3 9 Interconnecting Power Cord Ground Lead Connection All Models Tools Needed LTC 3 8 in 1 4 in gt The interconnecting power cord is not supplied with the unit Be sure to obtain the prop er interconnecting power cord for the welding power source the wire feeder is being con nected to 1 Strain Relief 2 Interconnecting Power Cord EF To ensure cord will be secure in strain relief slide supplied tub ing over cord Insert cord through strain relief Ground lead must be wrapped around ground current sensor to protect ground wi
38. it 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 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 CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage stor qe ER ERA n e POUR nea UTE RE ea 1 1 2 Arc Welding Hazards ups e d puce c ISSUE USE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 08 3 1 5 Principal Safety Standards 4 1 6 EME Information i rm ee ER OE a Saale x e
39. 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 Porteurs de stimulateur cardiaque rester danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologu es Ne pas souder dans un endroit 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 tran
40. lack Lead 115 VAC Hot C No Connection D No Connection E Red Lead 115 VAC Contact Closure Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Ref 802 310 Ref 193 749 OM 193 471 Page 18 3 19 Motor Start Burnback Control 8 e gt change wire feed starting speed 7 gt proceed as follows LF Turn Off unit welding power source Remove wrapper 1 Motor Board PC1 2 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment Adjust potentiometer R73 using a small nonconductive screwdriver Rotate potentiometer clockwise to increase time it takes the motor to ramp up to speed 3 Burnback Potentiometer R42 Remove protective white rubber cap before making adjustment Adjust potentiometer R42 using a small nonconductive screwdriver Rotate potentiometer clockwise to increase burnback time Reinstall wrapper Tools Needed Non Condu
41. les sont projet es pendant le soudage 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 incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels DES PI CES CHAUDES peuvent provoquer des br lures graves Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de
42. les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxyg ne provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger _ e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de puiv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs e
43. ls 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 193 471 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 ma
44. nd 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 la pince sur la piece aussi pres que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur medecin 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 INSTALLATION 3 1 Specifications Type of Input Welding Power Wire Feed Welding Overall Weight Power Source Type Speed Range Range Circuit Rating Dimensions 9 Hate Length 23
45. nlet wire A ERN eue 445 4 082 036 GUIDE wire RE 194 264 GUIDE wire inlet 3 32 in dia consisting of EC MUR 082 050 LINER monocoil inlet wire MM DNE 194 265 GUIDE wire inlet u a Grae bee Yen Len er bec 604 612 SCREW set 8 32x 12 cup pt sch stl es ics dn PLG4 115091 HOUSING PLUG amp I PLG3 115092 HOUSING PLUG amp PLG6 131 054 HOUSING amp SKTS RS 120 304 BLANK snap in nyl 250 mtg hole ai 107 983 BLANK snap in nyl 500 mtg hole TT 024 103 BLANK snap in nyl 750 mtg hole A ana 000 527 BLANK snap in nyl 875 mtg hole o SD LL Eua 010494 BUSHING snap in nyl 1 375 ID x 1 750 mtg hole Ec 134201 STAND OFF SUPPORT PC card 97 PCI 207272 CIRCUIT CARD ASSY motor speed control 8 ae alert 194 362 LABEL warning ground
46. nswers 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 2 Miller Effective January 1 2006 Equipment with a serial number preface of LG or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year af
47. on 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 Keep all doors panels covers 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 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
48. peed Control option Ref 802 310 A Ref 802 309 B OM 193 471 Page 20 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance A gt FEN u Disconnect power before maintaining d 3 Months On 39 Repair Or Clean And Replace MA Replace 7 Tighten Al Unreadable A Vy Cracked Weld labels Weld Cable Terminals N Be Replace Cracked 92 Parts Gun Cable Gas Hose Je 6 Months Blow Out Or Vacuum Er Inside Rolls During Heavy Service Clean Monthly 5 2 Overload Protection a e Turn Off wire feeder and X welding power source Stop engine on welding generator 1 Circuit Breaker CB1 CB1 protects motor from overload Correct problem and manually reset breaker 802 309 B OM 193 471 Page 21 5 3 Troubleshooting jn Trouble Remedy Wire does not feed unit completely inop erative Turn Power switch On Check circuit breaker CB1 see Section 5 2 Check Interconnecting control cord connections see Section 3 9 Check input power Wire does not feed Check circuit breaker CB1 see Section 5 2 Check gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Check ground current sensor see Section 3 9 Check welding circui
49. ration 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 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
50. ratoire nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste nn nn 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 Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes PC gt 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 43 DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels N que des ventilateurs e fermes et verrouilles les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettreles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lect
51. re against damage from weld current 3 Green Lead Ground Lead 4 Ground Current Sensor 5 Chassis Ground Stud w Hardware Wrap ground lead 5 times around ground current sensor Connect and secure end of ground lead to chassis ground stud 6 Terminal Block 1T E For welding power sources re quiring dry contact closure move lead 38 at terminal block to terminal D Refer to Sections 3 10 through 3 17 and make additional connections to terminal block 1T according to the applicable procedure Ref 802 310 3 10 Connection For L TEC Welding Power Sources With 7 Flat Socket Receptacle Tools Needed u E 1 4 in Make ground lead connections according to Section 3 9 before following this procedure 1 Terminal Block 1T 2 Interconnecting Power Cord 3 Green Lead Connected Ground In Section 3 9 Connect remaining leads to terminal block as follows A 115 VAC Neutral Lead B 115 VAC Hot Lead C No Connection D No Connection E 115 VAC Contact Closure Lead Secure strain relief clamp around cord Reinstall and secure wrapper to unit Connect remaining end of cord to welding power source Ref 802 310 Ref 193 749 OM 193 471 Page 14 3 11 Connection For Hobart Welding Power Sources With 19 Socket Receptacle Tools Needed E CAPO 1 4 in x Make ground lead connections accord
52. res OM 193 471 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 www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart 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 th
53. rique 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 Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c
54. rounn d S Rets CURRENT SENSOR T lt RC1 5 ES GREEN lt Rc1 2 lt lt RC1 6 NOTE FOR DRY CONTACT CLOSURE MOVE WIRE NO 38 TO TERMINAL 1T D RED 115VAC CONTACT CLOSURE E O z I RC6 1 ORANGE DRY CONTACT CLOSURE D 25 TE lt lt 2 CONNECTION 52 lt lt Rc4 1 Joc m v 1 lt lt Rc4 2 Z lt lt RC3 6 T1 BLACK 115VAC HOT BO si 35 115VAC 24VAC D NM lt 803 5 x 9 WHITE 115VAC NEUTRAL AO VALVE PURGE 1T CUSTOMER CONNECTIONS f lt lt Rc3 7 WARNING JN ELECTRIC SHOCK HAZARD Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit PC1 MOTOR CONTROL BOARD RC1 PLG1 RC3 PLG3 RC4 PLG4 RC5 PLG5 RC6 PLG6 RC3 1 gt lt lt c1 1 4 gt gt 65 gt gt 6 lt 2 RC3 3 gt gt 22 gt ee WIRE DRIVE MOTOR 4 ROLL RED 2 gt gt 5 gt 25 RC4 5 22 42 RC2 TRIGGER CONNECTION SEA cw RC4 7 gt HH RC5 5 er RC5 8 gt gt 5 5 1 gt TRIGGER HOLD 53 Rc5 9 gt gt r 7 PLG1 RCA RUN IN CONTROL TO MOTOR 4 gt 7 4 OPTION CONTROL Ax CONNECT TO BOARD RC1 5 gt gt 5 PLUG THAT gt WAS PLUGGED PLG4 RC4 2 INTO RCA 1 1 62 202 gt 6 JO START_COMMAND 9 2 5 gt g 6 gt gt 6 gt
55. sport 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 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 193 471 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
56. t for shorts to case activating ground current sensor Have Factory Authorized Service Agent check drive motor and control board PC1 Wire feeds erratically Readjust hub tension and drive roll pressure see Section 3 8 Use correct size drive roll see Parts List Clean or replace dirty or worn drive roll see Section 3 7 Remove weld spatter around nozzle opening Replace contact tip or liner See gun Owner s Manual Have Factory Authorized Service Agent check drive motor and control board PC1 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 feeds as soon as power is applied Check gun trigger See gun Owner s Manual Wire does not feed until trigger is pressed but continues to feed after trigger is released Check for short between gun trigger leads and weld cable Repair or replace gun trigger leads Gas does not flow wire feeds Check gas valve and flowmeter OM 193 471 Page 22 SECTION 6 ELECTRICAL DIAGRAM IMPORTANT ENSURE ADEQUATE GROUND PROTECTION WRAP GREEN GROUND LEAD THROUGH GROUND CURRENT SENSOR 5 TURNS TO PROTECT AGAINST THE RARE OCCURRENCE OF WELD CURRENT DAMAGING THE GROUND WIRE c RII lt lt RC1 4 CHASSIS GROUND P c
57. t former des gaz haute EN 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 193 471 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 tincel
58. te rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off weldin
59. ter 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 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batter
60. un 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 dans la Section 2 5 Lire et 6 pas enrouler les c bles autour du corps e USA Pa 3 Sila pi ce soud e doit tre mise la terre le faire directement avec un Seulun personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil Ne pas toucher l lectrode quand est en contact avec la pi ce la terre Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine H n n x sonnes notamment les enfants de l appareil Ne pas toucher des porte lectrodes connect s deux machines 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 Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures un r r js t 5 ji mi nt graves Le circuit de l lectrode et de la pi ce est ee el que ous GS PANNEAUX El couvercies sant correcem
61. witch Tools Needed 3 e 5 8 11 16 in 802 309 B OM 193 471 Page 10 3 6 Connecting Welding Gun Weld Cable 1 Gun Securing Knob 2 Gun Block 3 Outlet Wire Guide Loosen knob insert gun into block Position outlet wire guide as close as possible to drive rolls without touching Tighten knob 4 Gun Trigger Receptacle 5 Gun Trigger Plug 6 Weld Cable Terminal 7 Weld Cable From Welding a Power Source Tools Needed I 9 802 308 193 471 Page 11 3 7 Installing Wire Guide And Drive Roll Tools Needed IL 8 8 in 1 Inlet Wire Guide 2 Intermediate Wire Guide Install and secure inlet wire guide and intermediate wire guide 3 Drive Roll 4 Install drive rolls and turn drive roll nut one click During maintenance intervals remove drive rolls and clean grooves using a wire brush Check groove of drive roll for pitting or increase in the depth of the groove indicating drive roll is worn out 802 310 A OM 193 471 Page 12 3 8 Installing Threading Welding Wire sa 1 Retaining Ring gt gt 2 Tension Adjustment Nut If necessary move hub on support for use of different size wire spool Remove retaining ring and install spool so hub pin fits spool hole Re
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