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Miller Electric DVI-2 R User's Manual

1. Tools Needed ZS 3 4 in 19 mm 803 778 A Correct Installation Incorrect Installation A Turn off power before connecting to 1 Weld Output Terminal output terminal and secure with nut so that weld output terminals 2 Supplied Weld Output Terminal Nut es et minal is n Sg d ar Do not place anything between wel Failure to properly connect weld EE cable terminal and copier bar Make cables may cause excessive heat Copper Bat sure that the surfaces of the weld cable and start a fire or damage your ma Remove supplied nut from weld output ter terminal and copper bar are clean chine minal Slide weld cable terminal onto weld OM 232 386 Page 13 FF A complete Parts List is available at www MillerWelds com 4 5 Installing Work Cable And Clamp C Tools Needed IP 3 4 in 1 Work Cable 2 Boot Route cable through front panel opening Slide boot onto work cable 3 Negative Output Terminal Connect cable to terminal and cover connection with boot Close door 804 909 A 4 6 Setting Gun Polarity For Wire Type A ES Changing Polarity Wire Drive Assembly Lead Work Clamp Lead Positive Terminal Negative Terminal Shown as shipped Electrode Positive DCEP For solid steel stainless steel aluminum or flux core with gas wires GMAW
2. POS 24 28 Q O MOTOR DRIVE des HQUSING el rp a z H1 NEG A 25 E lt WORK c5 CLAMP rp H1 CONTROL i 59 BOARD RC3 2 gt D I RC3 1 0D pl 2 RC1 PLGI E d 2 RC2 PLG2 RC3 PLG3 RC3 6 el RC4 PLG4 C 55 RG6 FLG6 RC4 5 gt ROS PLCS PIN 1 4 PIN 2 RO4 6 DA Al 2 FLGIO PLG9 LED1 RC4 2 gt gt 1 gt RC4 1 gt 5 gt 2 gt RCI 3 gt gt RCI 4 gt RC 1 MIG RC4 3 gt 1 TRIC RC4 4 gt 12 Z TRIG RIN c c7 eT ITX RCS RC2 4 gt BZ 4 MTR RC2 3 gt 53 3 MR RC2 1 gt 37 Z TRIG j RC2 2 gt 28 1 TRIG RTN c9 Cp Gen STX ER SPOCLGUN OPTION SPOOL lt GSZ GUN 69 229 598 B OM 232 386 Page 31 SECTION 8 MIG WELDING GMAW GUIDELINES py da C si A 8 1 Typical MIG Process Connections Regulator Shielding Gas Flowmeter OM 232 386 Page 32 Gas Wire Feeder Power Source A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Workpiece Se Work Clamp mig1_2007 05 Ref 801 909 A 8 2 Typical MIG Process Control Settings gt These settings are guidelines only Material and wire type joint design fitup position shielding gas e
3. 3 ED Months all Unreadable Labels Q Weld Terminals Weld Cables Every 6 Months Q Inside Unit 1 Apply Light Coat Of Oil Or Grease To Drive Motor Shaft 6 2 Unit Overload Thermostats TP1 in rectifier SR1 and TP2 in stabilizer Z1 protect the unit from damage due to overheating If TP1 and or TP2 opens welding output will shut off and the Over Temp light will turn on Wait until Over Temp light turns off before trying to weld 6 3 Changing Drive Roll and Wire Inlet Guide 1 Securing Screw Ge SSC 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 4 13 4 Drive Roll Securing Nut Turn nut one click to secure drive roll Tools Needed Se 7 16 in Ref 804 914 A OM 232 386 Page 26 6 4 Aligning Drive Roll A complete Parts List is available at www MillerWelds com s and Wire Guide A Turn Off power View is from top of drive rolls looking down with pressure Tools Needed EE assembly open 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear I
4. Supply correct input power 2 Power Cord Connector 3 Plug NEMA Type 5 15P 4 Receptacle NEMA Type 5 15R Customer Supplied 5 Plug NEMA Type 5 20P Optional Receptacle NEMA Type 5 20R Customer Supplied 7 Plug NEMA Type 6 50P A Do Not cut off power cord connector and rewire The power cord 61 connector and plugs will work with standard NEMA receptacles Modifying power cord connector and plugs will void product A Do not move or operate unit where it could tip Ref 804 898 A 8 Receptacle NEMA Type 6 50R Customer Supplied Select plug for power supply receptacle available at site Install plug onto power cord adapter As threaded collar is tightened push plug onto adapter until collar is completely tight Connect plug to receptacle 9 Cylinder Support Bracket Holes in the bracket provide a location to store the unused power cord plugs OM 232 386 Page 19 A complete Parts List is available at www MillerWelds com 4 13 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight S NO G ARA MM Tools Needed EF Hold wire tightly to keep it from unraveling Pull and hold wire cut off end Push wire thru guides into gun continue
5. e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber 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 cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque 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 suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers sup
6. FCAW Drive assembly becomes negative Electrode Negative DCEN Reverse lead connections at terminals from that shown above for gasless flux core wires 1 Polarity Changeover Label Information Always read and follow manufac ture s recommended polarity LT 3 4 11 16 in Ref 190 821 A OM 232 386 Page 14 4 7 FF A complete Parts List is available at www MillerWelds com Installing Gas Supply Tools Needed IZ 1 1 8 5 8 in ur we 3 Rear Panel Obtain gas cylinders and chain to running gear wall or other stationary support so cylinders cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection For MIG Gun Connect gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Gas Flow Adjustment Control Typical flow rate is 25 cfh cubic feet per hour Check wire manufacturers recommended flow rate 8 CO2 Adapter Customer Supplied 9 O Ring Customer Supplied Install adapter with O ring between regulator flowneter and CO2 cylinder Re
7. OM 232 386B 2007 11 m Processes Miller a MIG GMAW Welding fe Flux Cored FCAW Welding FC Description 2 P2 F3 Arc Welding Power Source and Wire Feeder Millermatic DVI 2 OWNER S MANUAL Visit our website at File MIG GMAW pu www MillerWelds com b 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 1t any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 3 BU E E a 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 f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 00012000 of re
8. 8 7 Good Weld Bead Characteristics 36 8 8 Troubleshooting Excessive Spatter 37 8 9 Troubleshooting Porosity 37 8 10 Troubleshooting Excessive Penetration 37 8 11 Troubleshooting Lack Of Penetration 38 8 12 Troubleshooting Incomplete Fusion 4 eee eens 38 8 13 Troubleshooting Burn Through 2 eee eee eee 38 8 14 Troubleshooting Waviness Of Bead 39 8 15 Troubleshooting Distortion 39 8 16 Common MIG Shielding Gases 40 8 17 Troubleshooting Guide For Semiautomatic Welding Equipment 40 SECTION 9 PARTS LIST comico tai a SNE NEEN ices 42 COMPLETE PARTS LIST www MillerWelds com OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text A DANGER Indicates a hazardous situation which if NOTICE Indicates statements not related to personal injury 1 2 A
9. but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller 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 O 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA 8 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
10. see Section 4 13 Readjust hub tension see Section 4 8 Replace contact tip if blocked see welding gun Owner s Manual Clean or replace wire inlet guide or liner if dirty or plugged see welding gun Owner s Manual Replace drive roll if worn or slipping see Section 6 3 Check and clear any restrictions at drive assembly see Section 6 3 Have nearest Factory Authorized Service Agent check drive motor OM 232 386 Page 28 Notes OM 232 386 Page 29 SECTION 7 ELECTRICAL DIAGRAM amp WARNING e Do not touch live electrical parts gt e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC SHOCK HAZARD Have only qualified persons install use or service this unit OM 232 386 TS a I z SR1 f w BLK lt CB2 lt WHY Ge 10 230V 1 T i I i 1 I 1 115V i i I ji I i 1 lt REDI 5 len B COM GRN lt RC6 1 RECT AL RC6 7 f 1 POWER CORD W ADAPTER i CONFIQURATIONS 3 pega WHT RED m 5E K png_3 230V 6 50P H MIG 681 GUN O GRN 2 pen 4 RED BLK LEE Ro 115V 204 5 20P GRN ER Ret 2 RED BLK 115V 15A 5 15F GRN la J Figure 7 1 Welding Power Source Circuit Diagram Page 30
11. 990 A valve and barbed fitting Secure with hose clamps Remove snap in blank from front panel and Install supplied 4 position receptacle Connect plug from 4 position receptacle wiring harness into receptacle RC2 Connect capacitors to center baffle ground clip Reinstall wrapper OM 232 386 Page 21 FF A complete Parts List is available at www MillerWelds com 4 15 Connecting An Optional Spool Gun Sch NX X O X we ES E A B A d o 1 1 Barbed Fitting L7 If spool gun gas hose is equipped with a pre installed barbed fitting cut off fitting from end of hose Connect spool gun gas hose to barbed fitting 2 Gun Trigger Plug Insert plug into receptacle with spool gun symbol and tighten threaded collar 3 Negative Output Terminal 4 Positive Output Terminal Connect weld cable from spool gun to positive output terminal Close door 804 922 A OM 232 386 Page 22 FF A complete Parts List is available at www MillerWelds com SECTION 5 OPERATION 5 1 Controls S O N WIRE SPEED VOLTAGE a 60 2 3 70 2 0 1 90 DO NOT SWITCH WHILE WELDING Pee S OVERTEMP SA Ref 226 649 C 1 Voltage Control 2 Wire Speed Control 3 Over Temp Light Set Wire Speed control according to the Set Voltage control according to the parameter chart Increase or decrease wire If unit overheats light
12. W d 90 90 j 39 End View of Work Angle Side View of Gun Angle GROOVE WELDS 459 09 159 cs x A AOS End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 232 386 Page 34 8 4 Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage p 10 E Push PT 10 len C3 mn IA zune 4 Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT Le KL Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT A AAA ee Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 232 386 Page 35 8 5 Gun Movement During Welding CS Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads works better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 EE DDD S 0054 A 8 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration ODA M g
13. have been developed over the years The most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel eE Aluminum Argon X Argon 25 CO X 80 or greater Argon X xi balance CO or Oxygen 100 CO2 A Tri Mix X 1 Limited short circuiting use 2 90 HE 7 1 2 AR 2 1 2 CO 8 17 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but wire does not feed Too little pressure on wire feed rolls Increase pressure setting on wire feed rolls Incorrect wire feed rolls Check size stamped on wire feed rolls replace to match wire size and type if necessary Wire spool brake pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough s
14. preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of O to 15 degrees 8 13 Troubleshootin
15. tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage 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 Putilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 232 386
16. 386 Page 41 SECTION 9 PARTS LIST 9 1 Drive Roll And Wire Guide Kits LF Base selection of drive rolls upon the following recommended usages V Grooved rolls for hard wire U Grooved rolls for soft and soft shelled cored wires U Cogged rolls for extremely soft shelled wires usually hard surfacing types V Knurled rolls for hard shelled cored wires Drive roll types may be mixed to suit particular requirements e g V Knurled roll in combination with U Groovea 023 025 in 023 025 in 087 131 087 130 056 192 NDAO0N 030 035 in 030 035 in 0 8 0 9 mm 204 579 203 526 056 192 FF A complete Parts List is available at www MillerWelds com OM 232 368 Page 42 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Applet
17. 7 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd 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 Quincy MA 02269 9101 phone 617 770 3000 web site 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 7954 phone 1 866 512 1800 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 or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 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 Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction
18. ATION 5 21 Symboles ulises ad ed eas E oo ba Ts Se bt ono idu an et rid ka 5 2 2 Dangers relatifs au soudage l arc 6 nh 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Information EMF cesse ep pa ERA ee PRENSA REEL REX PUE IM 9 SECTION 3 DEFINITIONS 1 I xm taa REA 11 3 1 Symbols And Definitions irs pir ei ILIA eb CREE AA 11 SECTION4 INSTALLATION NN EEN Rye I ENNEN RENE NEE SNE NEEN NN RR 11 4 1 Specifications AA A kh NAS AR Cu AU a A iat Ad 11 4 2 Duty Cycle And Overheating 44444400444 12 4 35 Vol AMPEere e EE 13 4 4 Connecting To Weld Output Terminals 13 4 5 Installing Work Cable And Clamp 2 e Inn 14 4 6 Setting Gun Polarity For Wire Type 14 47 Installing Gas SUpply ciuda A AS aed a ASA ee GE N eR de 15 4 8 Installing MIG Wire Spool and Adjusting Hub Tension 16 4 9 Connecting 1 Phase Input Power For 230 VAC 17 4 10 Electrical Service Guide For 230 VAN 18 4 11 Extension Cord Data 4s A A A ias 18 4 12 Selecting A Location And Connecting
19. Input Power 19 4 13 Threading Welding Wie 20 4 14 Installing Optional Gas Valve Receptacle And Barbed Fitting For Optional Spool Gun 21 4 15 Connecting An Optional Spool Gun 22 SECTION 5 OPERATION e as a 23 5 1 ell TEE O O eae O babe O E eee bee E S RES 23 5 2 Weld Parameter Chart microondas dada Ba edle See gage dats 24 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 444 26 6 1 Routine Maintenance cse nero den Me dE chee Eed ved date ae 26 6 2 Unit Overload 1 2 been anse cats AE Ae EE SEN ee dE sas ae 26 6 3 Changing Drive Roll and Wire Inlet Guide 26 6 4 Aligning Drive Rolls and Wire Guide 27 6 5 Troubleshooting M ae A A EN E SEN ae ae de Se e be duele 27 SECTION 7 ELECTRICAL DIAGRAM 0 ccc cece cece I Inn K eee eee nnn 30 TABLE OF CONTENTS SECTION 8 MIG WELDING GMAW GUIDELINES 32 8 1 Typical MIG Process Connections 32 8 2 Typical MIG Process Control Settings 33 8 3 Holding And Positioning Welding Gun 34 8 4 Conditions That Affect Weld Bead Shape 35 8 5 Gun Movement During Welding 36 8 6 Poor Weld Bead Characteristics 36
20. Ontario Canada 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 cables de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apr s avoir exa min 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 lectriques 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 ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www a
21. Page 8 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 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 Protec tion Association P O Box 9101 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 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga
22. akers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT 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 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 MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating 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
23. al 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 Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation
24. ance is finished and before reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer 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 tronic equipment e Be sure this welding machine is installed and grounded according to this manual e If int
25. ancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N tiliser que les pi ces de rechange recom mand es par le constructeur Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F 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 installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que
26. arer cet appareil A Pendant le fonctionnement maintenir a distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIOUE peut 2 entrainer la mort Le contact d organes lectrigues sous tension peut provoguer des accidents mortels ou des br lures graves Le circuit de lectrode et de la pi ce est sous tension lorsgue le courant est d livr a la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talligues en contact avec le fil sont sous tension lectrigue Un guipement install ou mis a la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectrigues sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si lutilisation d une source lectrique courant lectrique s av re n ces
27. at www MillerWelds com Select Voltage mi ES and Wire Speed ai aa ESS ees Based on Thickness of 9 5 mm 6 4mm 4 8mm 3 2mm 2 0mm 1 2mm 0 8 mm Heat number E vcllge 5 90 ama aso 2 31 1 22 Hess wio peod 72 4 4 52 4 2 2 1 12 Parameter settings for 6 80 6 5 6 5 3 40 25 3 40 Parmeter 6 60 5 55 4 45 3 35 3 31 2 20 1 10 ege 5 90 gt 30v ONLY 5 87 4 68 4 55 aan 222 ny 6 60 5 50 4 43 4 37 3 23 2 11 f E E 10 90 6 52 5 45 5 40 4 35 3 25 3 17 2 10 6 100 Example Select Voltage and Wire Speed Based on Thickness DN mmm Lc of Metal Being Welded 3 8 i4 3 16 1 8 14ga 18ga 22ga read Settings 9 5 mm 6 4 mm 4 8 mm 3 2 mm 2 0 mm 1 2 mm 0 8 mm EE speed 5 64 4 54 au 2 30 1 16 Am 5 54 4 44 3 32 2 22 1h ECT ree Pr ANONY E 5 90 4 63 3 40 6 95 5 77 5 70 4 60 3 41 3 31 x 6 73 5 60 4 48 3 41 3 36 2 21 6 90 5 72 4 67 2 70 6 70 6 70 5 62 4 55 2 60 226 652 A OM 232 386 Page 25 FF A complete Parts List is available at www MillerWelds com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance o gt gt Ge ee A Disconnect power CS Maintain more often ST before maintaining during severe conditions E 14 Check Change Q Clean Replace Reference HA To be done by Factory Authorized Service Agent CE EX r P Every ex vii 2 AY Fe
28. ated 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 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 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 249 1 and Z87 1 listed in Safety Standards 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 Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If t
29. bsite www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 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 232 386 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 74
30. correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer 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 e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N
31. costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available
32. d plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after
33. ding 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 HE 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 Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers 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 norm
34. e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit nn nn e d F FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N J e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards SS N 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 3 STATIC ESD can damage PC boards K MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place n e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when mainten
35. erference 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 OM 232 386 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A 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 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 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 we
36. f 804 654 A Ref 804 898 A OM 232 386 Page 15 FF A complete Parts List is available at www MillerWelds com 4 8 Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring When a slight force is needed 61 with 8 in 200 mm spools to turn spool tension is set Installing 1 Or 2 Ib Wire Spool To install either a 1 Ib or 2 lb wire Spindle spool follow the procedure as P Install these shown in the illustration Spindle components onto spindle lt 9 Order extra spring Part No 186 437 Remove these components from spindle Tools Needed AG ED IC 15 16 in 072573 B 802 922 OM 232 386 Page 16 FF A complete Parts List is available at www MillerWelds com 4 9 Connecting 1 Phase Input Power For 230 VAC A Installation must meet all National and Local Codes have only qualified persons make this installation GND PE Earth Ground A Disconnect and lockout tagout input power before connecting input conductors from unit EZ A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals Connect green or green yellow grou
37. fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone etou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en por
38. g Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 232 386 Page 38 8 14 Troubleshooting Waviness Of Bead Wet CERNI Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal bd S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces i Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds OM 232 386 Page 39 8 16 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases
39. gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 8 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 232 386 Page 37 8 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion between weld metal and T m E base metal Good Penetration S 0638 Possible Causes Corrective Actions Improper joint
40. ge of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s A 115 VAC 150 opens output stops and cooling 125 fan runs Wait fifteen minutes for unit to cool Reduce amperage or 100 duty cycle before welding A NOTICE Exceeding duty cycle e can damage unit or gun and void ii 73 warranty o lt o 50 Li m 57 5 25 0 10 15 20 25 30 40 50 60 70 8090100 DUTY CYCLE 2096 duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting B 230 VAC BE EE 400 350 300 2 250 tr HI 200 gt lt 150 a I LU 100 50 DUTY CYCLE 40 duty cycle at 150 amps E 4 Minutes Welding 6 Minutes Resting Overheating ES 0 AorV byl NS Rx 15 i OR R D Minutes educe Duty Cycle duty1 4 95 124 655 220 896 A OM 232 386 Page 12 FF A complete Parts List is available at www MillerWelds com 4 3 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown LF Ranges 4 5 and 6 apply to 230 VAC only Range 6 Range 5 DC VOLTS Range 4 Range 3 Range 2 Range 1 0 50 100 150 200 250 DC AMPERES ssb1 1 10 91 199 212 4 4 Connecting To Weld Output Terminals Do not place anything between weid cable terminal l and copper bar
41. heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som_2007 04 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on V vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage a l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit A Seul un personnel qualifi est autoris a installer faire fonc tionner entretenir et r p
42. his 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 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 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 Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 OM 232 386 Page 2 CND 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 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit bre
43. le de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encasde non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SA Eo LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caille
44. lete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbols And Definitions Do Not Switch olo Wire Feed e Output X Duty Cycle a While Welding V Volts Increase On O Off Gas Metal Arc CG Welding GMAW Sp Wire Spool L Gas Input gt Gas Output Gun Voltage Input y Press To Reset U Rated No Load Voltage Average SECTION 4 INSTALLATION 4 1 Specifications A 115 VAC y o Amperes Input at Rated Rated Welding Maximum Open Cir Amperage Range Load Output 115 V 60 Hz KVA KW Output cuit Voltage DC Single Phase 90 A 18 0 Volts DC 20 Duty Cycle 30 135 32 24 8 2 78 2 23 B 230 VAC P Amperes Input at Rated M Amperage Range Maximum Open Gi Load Output 230 V 50 60 KVA KW P g Hz Single Phase 150 A 23 Volts DC 40 Duty Cycle 30 175 32 25 0 5 74 4 93 C General Specifications Wire Feed Maximum Net Weight Wire Type and Diameter Speed Spool Size Dimensions Without Gun Solid Stainless Flux Cored Aluminum 50 700 IPM 12 in 305 mm H 30 in 762 mm 158 lb 023 035 in 030 035 in 030 035 in 2 m s dx Ge d XS 0 6 0 9 mm 0 8 0 9 mm 0 8 0 9 mm P OM 232 386 Page 11 FF A complete Parts List is available at www MillerWelds com 4 2 Duty Cycle And Overheating Duty Cycle is percenta
45. liable service with proper maintenance And for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in d be exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 11 Symbols age oe te tent E e oe dd PE O E ne ms 1 1 25 Arc Welding Llazatrds on hee rt it et TE Ru EE ex E 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 4 150 JZEMEINTOrmation dee eren ro de e pl ments Bero d M erste dull ster nc ow 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILIS
46. ment le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer 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 CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester a distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ou 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 sou dage les manipuler avec pr caution
47. nal Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements 4 11 Extension Cord Data LEF When calculating max cord length remember to include conductor length from line disconnect device to input power receptacle Input Power Input Voltage Phase Conductor Size Max Cord Length OM 232 386 Page 18 FF A complete Parts List is available at www MillerWelds com 4 12 Selecting A Location And Connecting Input Power 18 in 457 mm of space for airflow Ny MA TS M Y H A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 For 115 volts ac input power a 15 or 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required For 230 volts ac input power see Section 4 9 1 Rating Label warranty
48. nding conductor to disconnect device grounding A terminal first disconnect device line terminals 7 Over Current Protection ML Select t d si f L2 L1 ype and size of over current al protection using Section 4 10 fused Ai II o K disconnect switch shown 8 Receptacle NEMA 6 50R n Customer Supplied 230 VAC 1 v Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position NI Connect input conductors L1 and L2 to Tools Needed Esc Be 803 766 B Ref 802 443 A OM 232 386 Page 17 FF A complete Parts List is available at www MillerWelds com 4 10 Electrical Service Guide For 230 VAC A Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard These recommendationsare for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source 60 Hz Single Phase Input Voltage 230 Input Amperes At Rated Output 25 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker Time Delay 2 30 Normal Operating 35 Min Input Conductor Size In AWG 4 12 Max Recommended Input Conductor Length In Feet Meters Min Grounding Conductor Size In AWG 4 12 Reference 2005 Natio
49. nsert screwdriver and turn screw in or out until drive roll groove lines up with wire guide Correct Incorrect Close pressure roll assembly Ref 800 412 A 6 5 Troubleshooting Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle see Section 4 12 Check power switch supplementary protector and reset if necessary If supplementary protector is not tripped replace power switch Replace building line fuse or reset circuit breaker if open see Section 4 12 Thermostat TP1 or TP2 open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 6 2 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section welding gun Owner s Manual Low weld output Connect unit to proper input voltage or check for low line voltage see Section 4 12 Low high or erratic wire speed Readjust front panel settings see Section Change to correct size drive roll see Section 6 3 Readjust drive roll pressure see Section 4 13 OM 232 386 Page 27 A complete Parts List is available at www MillerWelds com Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts see welding gun Owner s Manual Adjust drive roll pressure
50. nsi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet 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 de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 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 soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 232 386 Page 9 OM 232 386 Page 10 FF A comp
51. o it does not touch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas oylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Loose or broken wires to gas solenoid Have Factory Authorized Service Agent repair wiring Gas solenoid valve not operating Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage OM 232 386 Page 40 Problem Probable Cause Remedy Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 232
52. on 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 delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Wel
53. pl 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 pro duits 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 ue 1 L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT s Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal Se e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage ei les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuv re est ex cuter dans un endroit s r lorsque l on
54. porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s SIS So N e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures 3 ei e Nepas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 232 386 Page 7 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 per sonnes ou toute pi ce m canique en enga geantle fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures CA e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebr
55. rc Welding Hazards A 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 A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away m ELECTRIC SHOCK can kill 0 Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process If AC outpu
56. removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed 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 i OM 232 386 Page 1 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 react with vapors to form highly toxic and irritating gases Do not weld on co
57. saire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante Fx Indique des instructions sp cifiques e PF Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC a fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste
58. securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard d e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit
59. t S 0053 A 8 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 NoOverlap 5 Good Penetration into Base Metal S 0052 B OM 232 386 Page 36 8 8 Troubleshooting Excessive Spatter iii Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead ko Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 8 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal LAU Possible Causes Corrective Actions Insufficient shielding
60. t is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions PK This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cor
61. tant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri 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 votre casque 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 sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 232 386 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pel provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce cha
62. tc affect settings Test welds to be sure they comply to specifications Material thickness determines weld parameters Us 1 8 or 0 125 in Convert Material Thickness to L Amperage A ii 0 001 in 1 ampere 0 125 in 125A Wire Size Amperage Range 4 d 0 023 in 30 90 A 0 030 in 40 145A Select Wire Size 0 035 in 50 180 A Wire Wire Speed Select Wire Speed Size Recommendation Approx Amperage 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inches per minute y Low voltage wire stubs into work High voltage arc is unstable spatter Select Voltage Set voltage midway between high low voltage Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate OM 232 386 Page 33 8 3 Holding And Positioning Welding Gun CS Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 2 3 4 Electrode Extension Stickout PA 1 4to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 deer 09 159
63. to hold wire L Use pressure indicator scale to set a desired drive roll pressure Tighten Pressure Indicator Scale AN gt Io OFF Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire Tighten EPA 5 by m y 32 y WOOD 4 Press gun trigger until wire Feed wire to check drive roll pressure Cut off wire Close d comes out of gun Reinstall Tighten knob enough to prevent slipping and latch door contact tip and nozzle Ref 804 897 A OM 232 386 Page 20 FF A complete Parts List is available at www MillerWelds com 4 14 Installing Optional Gas Valve Receptacle And Barbed Fitting For Optional Spool Gun 3 Pa T Tools Needed CFF 1 4 in fgi6i L ZE Le eu A Turn Off unit and disconnect input power Remove wrapper 1 Rear Panel 2 Snap in Blank Location 3 Center Baffle Barbed Fitting Hole Location 4 Front Panel 5 Center Baffle Ground Clip 6 Circuit Board PC1 7 Receptacle RC1 8 Receptacle RC2 Remove snap in blank from rear panel and install supplied gas valve Connect plug from gas valve wiring harness into receptacle RC1 Install supplied barbed fitting into center baffle hole Connect gas hose between gas 804
64. turns on and output parameter chart for good starting point speed to obtain desired bead profile and stops Allow unit to cool before resuming Turn control clockwise to increase voltage travel speed operation OM 232 386 Page 23 FF A complete Parts List is available at www MillerWelds com 5 2 Weld Parameter Chart Suggested Shielding Gases Wire Sizes And Flow Rate Diameters 75 Ar 25 CO 25 c h Ar CO 002a UL produces less 0 030 0 8mm 0 035 0 9mm 100 CO 25 cfh 0 023 0 6mm 0 030 0 8mm 0 035 0 9mm Suggested Shielding Gases Wire Sizes And Flow Rate Diameters STEEL No shielding gas 0 030 0 8mm required 0 035 0 9mm STAINLESS i Tri Mix 35 c h 9 0237 0 6mm 0 0 STEEL 90 He 7 5 Te 939 0 8mm Ar 2 5 CO 0 035 0 9mm 0 030 0 8mm 0 035 0 9mm Aluminum with i 100 Ar 25 cfh optional Spoolmate 3035 spoolgun X Line voltage can affect weld output settings on this chart are starting values only You may need to adjust voltage and wire feed speed to optimize your settings Input Line Parameter Voltage Chart Settings Higher Weld Will Be e g 240 Or Hotter Volts AC Lower Settings Use Parameter 230 Volts AC gt Chart Lower Weld Will Be e g 218 Colder Volts AC Raise Settings OM 232 386 Page 24 FF A complete Parts List is available
65. udes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier e s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e 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 par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possib
66. utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 232 386 Page 5 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 indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures A LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des

Miller Electric DVI-2 R User's Manual

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