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Miller Electric Dimension NT 450 User's Manual

1. V A fe LS TIG GTAW 85 Blank Preset Amps V A G MIG GMAW 24 5 Preset Volts Blank V A ey cc 85 I Blank Preset Amps V A TL Stick SMAW 78 0 85 Actual Volts OCV Preset Amps V A 6 Voltage Sensing 78 0 Flashes OCV And Preset Volts Blank 5 3 Lift Arc TIG Procedure For CC CV Models Touch Do NOT Strike Like A Match With Mode switch in the Lift Arc TIG position start an arc as follows 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work piece at weld start point hold electrode to workpiece for 1 2 seconds and slowly lift electrode An arc will form when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contaminated Ref S 156 279 OM 2252 Page 23 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance gt apr gt Disconnect power before maintaining E Maintain more often during severe conditions 17 Check Change Q
2. 29 6 4 Tro bleshootihg edge erm 26 SECTION 7 ELECTRICAL ccc eee eee eee eee III n nnn 28 SECTION S PARTS LIST 4 A e mea sie dae RUPEM n E err mr done ERE ra e 30 OPTIONS AND ACCESSORIES WARRANTY Notes SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 A Protect yourself and others from injury read and follow these precautions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situation which if 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 NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A Le 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 a
3. 2 16 4 6 TIPPIAG RE oot EHE NR IM a IURE UR E 17 4 7 115 VAC Receptacle And Circuit Breakers 17 4 8 Weld Output Terminals And Selecting Cable Sizes 18 4 9 Connecting Weld Output Cables ahh 18 4 10 Remote 14 Receptacle Information 0 060 eee eee 19 4 11 Connecting Remote Control 19 4 12 Electrical Service Guide 20 4 13 Placing Jumper dae a a a a a a dee 20 4 14 Connecting Input Power ened hh hne 21 SECTION 5 OPERATION 55255 sms cerises nie eine E gece Mike ea soaie pes ersten ee 22 5st Controls Sc ose Rp AR ti ee dead seo ceed bins eR EN lee 22 5 2 Meter Functions For CC CV Models 23 5 3 Lift Arc TIG Procedure For CC CV Models 23 SECTION 6 MAINTENANCE amp TROUBLESHOOTING euc 24 6 1 Routine Maintenance tee elektr nent Ra E PR ee race ee e FR EAMUS tals 24 6 2 FUSE ET voe eee De ERO ER ME 24 6 3 Voltmeter Ammeter Help Displays
4. 1 601835 NUT 10 32 BRASS 24 UT 038887 STUD PRIMARY BOARD BRS 10 32 X 1 375 24 010913 WASHER FLAT 218IDX0 4600DX 031T BRS 24 uite 038 618 LINK JUMPER TERM BD PRI 8 we does tees 212095 BAFFLE AIR una y epp eee eb dle eid eee ele 1 16 T2 159042 XFMR CONTROL 50VA 24V 230 460 575 PRI 60HZ 1 16 T2 159043 XFMR CONTROL 50VA 24V220 380 400 415 440PRI 50HZ 1 wit T a erat andes farts 162816 CHANNEL UPRIGHT Socinano anae E a e o AOR Ai n 4 ti WB LEEA E 163359 BASE eua aed e x e uS a e e 1 19 SR1 207663 RECTIFIER SI DIODE 500 AMP 1 20 T1 224297 XFMR POWER MAIN 230 460 575 1 20 T1 285869 XFMR POWER MAIN 380 400 440 1 TH1 223386 THERMISTOR NTC 10K OHM 25 DEG C 34IN LEAD 1 dec RC16 17 212420 HOUSING RCPT PINS SERVICE KIT 3PIN 5PIN 1 gants PLG16 17 217 885 HOUSING PLUG SKTS SERVICE KIT 8 SKT 5 SKT 1 cache ed e idees 212316 BRACKET MOUNTING IGBT ASSEMBLY 2 suba rene st set 179 276 BUSHING SNAP IN NYL 1 000 ID X 1 375 MTG HOLE
5. Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 2252 Page 27 SECTION 7 ELECTRICAL DIAGRAM FROM CONTACTOR OR SWITCH 3 OPTIONAL PRIMARY 380 400 440 PRIMARY 6 TI FACTORY OPTION FAN CIRCUIT FROM INPUT POWER WARNING e 9 9 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 T1 D3 OM 2252 Page 28 PC1 CONTROL BOARD 6 p 575V a 8 LE TO PCI AA 4 3 a a A n2 230v B an 25 ri B mz TDT mv 5 cel lez ca FM EL 4 v 230v s PRI 5 LL SEC p 3 h i t 5 B D4 D5 TAL AA gom co joi i 5 DO i 5 E RC16 PLGIG 1e 1 o H H B Ax 1 lt 6 WO amp E De RED 1 lt OF BLK z C
6. Press button to reset breaker Ref 800 166 D OM 2252 Page 17 4 8 Weld Output Terminals And Selecting Cable Sizes A Turn Off power before Total Cable Copper Length In Weld Circuit Not Exceeding connecting to weld 100 ft 30 m Or Less 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft output terminals 45 m 60 m 70 m 90 m 105 m 120 m 10 60 rs e Duis eck 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 Positive Negative 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Terminal 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 E 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 700 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes Correct Installation A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your ma chine Weld Output Termina
7. OM 2252 218 084R 2008 01 i er Processes Multiprocess Welding K Description Arc Welding Power Source Dimension NT 450 And Dimension NT 500 OWNER S MANUAL File Multiprocess Welding ot t www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 3 BI E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 00012000 of reliable service with pr
8. fefe lefefo le Ref 800 103 A OM 2252 Page 20 4 14 Connecting Input Power Per GND PE Earth Ground T bp oppo mom z O o Tools Needed 1 2 in C 3 8 in p GND PE Earth Ground A Installation must meet all National and Local Codes have only quali fied persons make this installation A Disconnect and lockout tagout in put power before connecting input conductors from unit A Make input power connections to the welding power source first A Always connect green or green yel low conductor to supply grounding terminal first and never to a line ter minal See rating label on unit and check input volt age available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 12 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor 5 Reed Switch Ground Current Sensor Optional Connect green or green yellow grounding
9. Clean A Repair Replace To be done by Factory Authorized Service Agent und 4 WARNIN 3 6 Months vil e il X Labels Weld Terminals Every 3 0 Months Oss di Au AN PA gt XCables And Cords alll Every 6 Months 7 Q Durning heavy service clean monthly 6 2 Fuse F1 Disconnect input power be ER fore opening rear access door E 1 Fuse See Parts List For Rating Fuse F1 protects control transform er from overload If F1 opens weld output and fan motor stops Re place F1 Close door when finished Tools Needed F 3 8 in Ref 800 101 C OM 2252 Page 24 6 3 Voltmeter Ammeter Help Displays EF All directions are in reference to the front of the unit All circuitry referred to is located inside the unit 1 Help 0 Display Indicates a shorted thermistor in the transformer of the unit If this display is shown contact a Factory Autho rized Service Agent 2 Help 2 Display Indicates a malfunction in the thermal protection circuitry located on the transformer of the unit If this display is shown contact a Factory Authorized Service Agent lt 3 Help 3 Display Indicates the transformer of the unit has overheated The 2 unit has shut down to allow the fan to cool it see Section 4 2 Operation will continue when the unit has cooled P 2 4 Help 4 Display Indicates a malfunction in the thermal protect
10. 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 entra ner 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 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 tiliser 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 fa on obtenir un bon contact m tal m tal avec la pi ce souder o
11. 010 467 CONN CLAMP CABLE 1 250 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2252 Page 35 5 Hardware is common and not available unless listed 803 936 A Figure 8 4 Panel Rear With Components Item Dia Part EN No Mkgs No Description Quantity Figure 8 4 Panel Rear With Components Fig 8 1 Item 9 qe 173283 CHAMBER 4 1 ETE 180 165 BLADE FAN 14 IN 3WG 28DEG 375 BORE CCW 1 nis eg genera 162807 PANEL BEAR une kb eR EX NR ee UE XN YE Re E Rois 1 168343 HINGE DOOR PRIMARY 2 TL p 162 818 DOOR ACCESS 1 ouis Does eue xu 217 733 LABEL WARNING ELECTRIC SHOCK INPUT POWER EN FR 1 179 290 LABEL WARNING ELECTRIC SHOCK INPUT CONNECTION CEW 1 inc 602 177 SCREW SET 250 20 X 250KNRLPT SCH STL 2 eee 124 274 BRACKET MTG FAN MOTOR 1 he us FM 208 402 MOTOR 1 12HP 230V 1550RPM 50 60HZ 83A 1 EE 010467 CONNECTOR CLAMP CABLE 1 250 1 When ordering a component originally display
12. 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 2252 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 416 747 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 Quin
13. 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 ca 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 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 reconnait 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 base de plomb produits chimi ques dont l Etat de Californie reconnait 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 2252 Page 8 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait 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
14. 5 2 4 Mode Switch Use Mode switch to determine both process and output On Off control Orange areas highlight contactor on positions 5 Panel Remote Control Switch For front panel control place switch in Panel position and use the V A Adjust control to set amperage or voltage depending on Mode Switch selection For remote control make connections to Re mote 14 receptacle see Section 4 11 and place switch in Remote position In TIG modes output available through the remote control is a percent of the V A Adjust control setting Value selected on V A Adjust control is maximum output available through the re mote control In the MIG CC and V Sense feeder modes a remote control provides full range of unit output regardless of V A Adjust control setting A remote control is not func tional in Air Carbon Arc or Stick modes If connection to Remote 14 receptacle is re moved and Panel Remote control switch re mains in Remote position output is controlled with the V A Adjust control 6 V A Voltage Amperage Adjust Control With Mode switch in any Stick or TIG position use control to adjust amperage from 5 to 500 amps With Mode switch in a V Sense Feeder or MIG position use control to adjust voltage from 10 to 38 volts 7 Inductance Dig Control Control adjusts Dig when a Stick or CC mode is selected on mode switch When set to wards minimum short circuit amperage at low arc voltage is the same as norma
15. CENT 1 Ves d esee aura Fig 8 3 ASSEMBLY IGBT CAPACITOR 1 EIL 234503 COVER IGBT CAPACITOR ASSEMBLY 1 S ubl gd 057 358 BUSHING SNAP IN NYL 1 000 ID X 1 375 MTG HOLE 1 190 512 STAND OFF NO 6 32 X 640 LG 250 HEX AL FEM 6 27 PC1 222309 CIRCUIT CARD ASSY CONTROL 1 seta PLG8 RC2131 204 HOUSING PLUG amp SOCKETS 1 ELM PLG4 RC4 115 093 HOUSING PLUG amp SOCKETS 1 RE PLG5 RC5 115 094 HOUSING PLUG amp SOCKETS 1 TORUM PLG6 RC6 115 092 HOUSING PLUG amp SOCKETS 1 d E PLG7 RC7131 054 HOUSING PLUG amp SOCKETS 1 Dur eee 234502 COVER PC BOARD 0 1 sue PO esie nga 212594 BAFFLE AIR iis coe coe nigel dite m eter rhe RE RR E eek aaa ons 1 xs e acre 193462 BRACKET MOUNTING CONTACTOR 1 wesley ZT 32236955 oe STABILIZERS bis civ a nhl ae IRURE ER dt cbr iE RS 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested R
16. FRONT PANEL amp DISPLAY NT 500 MODELS CIRCUIT CARD ASSY FRONT PANEL amp DISPLAY NT 450 MODELS HOUSING PLG SKTS SERVICE KIT EBEGTRONICS BOX co resonet M D ERU Reni d CONNECTOR CIRC MS PROTECTIVE Description Figure 8 2 Panel Front With Components Fig 8 1 Item 1 PANEL FRONT TERMINAL PWR OUTPUT RED CAPACITOR CER DISC 1 UF 500 VDC W TERMS SPRING CPRSN 600 OD X 072 WIRE X 1 500 PLD TERMINAL PWR OUTPUT BLACK PLATE CONTROL LOWER LABEL WARNING ELECTRIC SHOCK AND REDUCED AIR LABEL ELECTRIC SHOCK REDUCE AIR FLOW CE CIRCUIT BREAKER MAN RESET 1P 15A 250VAC FRICT RCPT STR DX GRD 2P3W 15A 125V RECEPTACLE CAPACITOR SWITCH W LEADS Includes RCPT W SKTS SERVICE KIT MODULE FILTER 1MF X 9 500VDC W GND CONN RECT INSULATION DISPLACEMENT CAPACITOR CER DISC 1 UF 500 VDC STRIP CAPACITOR CER DISC 01 UF 1000 VDC STRIP BUSHING SNAP IN NYL 1 375 ID X 1 750 MTG HOLE STRAP GROUNDING 5 50 IN LONG TRANSDUCER CURRENT 1000A MODULE MAX OPEN LOOP LABEL WELD CABLE LUG LABEL OUTPUT TERMINAL CONNECTION CABLE RIBBON 24 POSN 14 000 IN SKTS BE SWITCH ROTARY 2 POSN 1P 10A 125VAC SOLDER 180DEG Quantity When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when
17. Locate unit near correct input pow Movement er supply Location 5 A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 If using lifting forks extend forks beyond opposite side of unit 3 Plate Label 4 Rating Label CE Models Typical Use rating label to determine input power needs 5 Line Disconnect Device 18 in 460 mm i gt OM 2252 Page 15 4 5 Dimensions And Weights Dimensions 30 in 762 mm including lift eye 23 in 585 mm 38 in 966 mm including strain relief 35 in 889 mm 1 1 4 in 32 mm 21 1 8 in 537 mm 1 1 8 in 29 mm IIO nm ou 7 16 in 11 mm Dia Weight 376 Ib 171 kg a We 4 4 Holes Front 800 453 A 801 530 OM 2252 Page 16 4 6 Tipping um A Do not move or operate unit where it could tip 4 7 115 VAC Receptacle And Circuit Breakers A Turn Off power before connecting to receptacle 1 115V 15 A AC Receptacle RC15 Power is shared between RC15 and Remote 14 receptacle RC14 see Section 4 11 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects the 115 volts ac por tion of RC14 and RC15 from overload CB2 protects the 24 volts ac portion of RC14 from overload
18. 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 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 9 Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit T OVERUSE can cause OVERHEATING e 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 N FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and fac
19. in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual 9 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 ne 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 pr
20. lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage 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 e 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 2252 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 pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes 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 surchau fement ou un incendie Avant de commencer le soudage v rifier 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 soud
21. 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 Enn L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT pa e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal River 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 N LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s AS 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 an
22. 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 ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 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
23. separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor 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 normal wear Exception brushes slip rings and re
24. that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted
25. warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
26. 0 Hz 7 4 2 2 22 21 450 Amp Volts DC 100 3 i k 39 2 i Duty Cycle 78 VDC In 2 18 1 11 1 05 950 1 04 0 84 0 87 0 29 CV Mode For 10 38V In CV 60 Hz Mode 80 VDC In CV Mode For 50 Hz While idling 4 2 Duty Cycle And Overheating WELD AMPERES 100 Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 10 20 30 40 50 70 80 90 100 DUTY CYCLE 100 Duty Cycle O Continuous Welding Overheating e e Minutes ES AN OR Reduce Duty Cycle duty1 4 95 210 976 B OM 2252 Page 13 4 3 Volt Ampere Curves Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown A CC Mode DC Voltage 10 0 T T T T T 0 100 200 300 400 500 600 DC Current B CV Mode DC Voltage DC Current va_curvel 4 95 212 111 A 212 112 A OM 2252 Page 14 4 4 Selecting A Location 5 VAY m 1 Lifting Eye 7 2 Lifting Forks Use lifting eye or lifting forks to zu move unit
27. DUP OF GAS can injure or kill e Shutoff 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 9 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 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
28. E Figure 8 1 Main Assembly Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly EPI Fig 8 2 PANEL Front w Components 1 217 136 WARNING ELECTRIC SHOCK 2 s FAT x 176 254 LABEL GENERAL PRECAUTIONARY WORDLESS INTL 2 MEC 1179432 PANEL SIDE Re e xe oat xe RR Gear a 2 iod 179 431 aes COVER TOPS 2 lla op ee imd USE e Soy qa 1 Ab 213 898 BAFFLE AIR UPPER IGBT ASSY 1 PN T 162800 LIE T EYE esis se brain nm te Ee e eda ROG BEN n andes 1 Dur P 177279 a GASKET LIFT EYE cre CES Or RR E or RERO PE 1 vC tnt T02 820 BAR MTG LIFT EY E s i eee eere Rente neo aee RC ER SIRE Baden rare 2 Mx Oscar rho Fig 8 4 PANEL REAR i eR ex Reale ae i ae IN Ey SE 1 10 C21 2223163 906 CAPACITOR oi is ek Avus exe hd AR DE RATE LR UN EA E Eee el 3 159 034 HOLDER FUSE MINTR 10 3MM X 33 3 TO 38 1 MM PANEL MT 1 12 F1 196065 FUSE CRTG 5 AMP 600 V TIME DELAY 1 13 W 160793 CONTACTOR DEF PRP 60A 3P 24VAC COIL W BOXLUG 1 OM 2252 Page 30 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly Continued 14 159244 PRIMARY BOX Includes
29. NT 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 but may vary from province to province miller
30. ROB S 3 e g mer Ur RED lt n 4 RCB B rH s 5 amp W Kez BK lt 45 C RCB 7 CBI RC17 PLG17 FED RED 1 Zl C rca 1 E 415V P 2 lt 2 2 Reis 682 YEL z X RED 2 Z LRO i BR GR SIL JF ta flat Oo Pe ca M7 cB m mum Rc A Figure 7 1 Circuit Diagram For Dimension NT R6 R3 lt lt RC7 1 lt x RC7 2 TO FAN MOTOR CIRCUIT RCA 4 c1 MOD 1 AS oN TS E1 l BRE EZ eZ 4 n 29 Les pies WW Wa sae 2 gli RC5 3 gt gt eo LT ROS 1 gt 0 MOD 2 RCS Z gt ROS 4 gt 5 gt gt res DT Rez 1 RCZ 3 gt gt N T CABLE EY zu Bi Aa amp x SE Bg FEES E AA A A L A hod e yann o 1 1 1 1 b FOR ddd og OoO0 dcc ocococt E E E IDE E VVVVVVM V M CAPACITOR Les RMT MODULE 1 E AN AN AN AINA AN AN AN PANEL 218 081 F OM 2252 Page 29 SECTION 8 PARTS LIST 5 Hardware is common and not available unless listed CN 3 803 896
31. afety 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 Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 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 website 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
32. age 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 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 e 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 cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en 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 En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porte
33. 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 Porteur de simulateur cardiaque ou autre im plants m dicaux rester 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 ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution 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 ci
34. ck for proper jumper link position see Section 4 13 Check fuse F1 and replace if necessary see Section 6 2 Meter displays a HELP message If meters display a HELP message see Section 6 3 No weld output pilot light PL1 on Check for open line fuse s and replace if open see Section 4 14 Check for proper input power connections see Section 4 14 Check for proper jumper link position see Section 4 13 Unit overheated Allow unit to cool with fan On see Section 4 2 If using remote control place Panel Remote control switch in Remote position and connect remote control see Sections 4 11 and 5 1 If remote is not being used place switch in Panel position see Section 5 1 Check repair or replace remote control Limited weld output and low open circuit voltage Check position of Panel Remote control switch see Section 5 1 Check for open line fuse s and replace if open see Section 4 14 Check for proper input power connections see Section 4 14 Check for proper jumper link position see Section 4 13 Clean and tighten all weld output connections Unit provides only maximum or mini mum weld output Check position of Panel Remote control switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 front panel display board PC2 and hall device HD1 Erratic or improper weld output Use proper size and type
35. conductor to welding power source ground ing terminal first If unit is equipped with op tional ground current sensor route ground ing conductor through reed switch two times and connect to grounding terminal 6 Welding Power Source Line Terminals 7 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line ter minals Close and secure access door on welding power source Disconnect Device Input Power Connec tions 8 Disconnect Device switch shown in OFF position 9 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first 10 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals 11 Overcurrent Protection Select type and size of overcurrent protec tion using Section 4 12 fused disconnect switch shown Close and secure door on line disconnect device Remove lockout tagout device and place switch in the On position 800 103 C Ref 801 116 A OM 2252 Page 21 5 1 SECTION 5 OPERATION Controls 23 AS 1 Power Switch gt This unit is equipped with a fan motor that is thermostatically controlled and only runs when cooling is needed 2 Voltmeter see Section 5 2 3 Ammeter see Section
36. cy 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 4 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 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 l vite pas peut donner la mort ou des blessures grav
37. 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 2252 Page 9 OM 2252 Page 10 SECTION 3 DEFINITIONS 3 1 General Precautionary Label 6 176 254 B Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from wo
38. e 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 Puton grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards SS e MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 4 9 STATIC ESD can damage PC boards x MOVING PARTS can cause injury NU 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 reconnecting input power e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place 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 equipme
39. e 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 13 Placing Jumper Links RP SN Tools Needed 3 S 3 8 in CLEO 3 8 in tO ih In A Disconnect and lockout tag out input power before installing or moving jumper links Check input voltage available at site 1 Jumper Link Label Check label 2 Jumper Links Move jumper links to match input voltage Close access door or go on to Section 4 14 ooo S174973B 575 VOLTS 80 VOLTS 400 VOLTS 440 VOLTS okligdo o olligdooo olgigdo o o o o o o olgfalo o o o o o olglia o coke o ollo o o glglo 220 VOLT OPTIO Moldeo s o alalola
40. ead 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 2252 Page 2 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 breakers 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 BUIL
41. en the primary voltage rises more than 1296 above the linked primary voltage setting for more than 30 seconds The display flashes a HELP 7 message during idle but the welder continues to operate normally Once the pri mary voltage returns to less than 1096 above the linked 7 primary voltage setting the flashing error ceases The shutdown stage occurs when the primary voltage rises more than 2096 above the linked primary voltage setting for more than 30 seconds A constant HELP 7 message is displayed and weld output is disabled Once the primary voltage returns to less than 1096 above the linked primary voltage setting the constant error message ceases and weld output is enabled lt T Mmi lt L mMm i T N lt SE i NOTE Operating the welder out of the normal operating range 12 of the linked primary will affect the output and reliability of the welder and is not recommended 8 Help 9 Display Indicates a shorted thermistor on the secondary heat sink of the unit If this display is shown contact a Factory Authorized Service Agent OM 2252 Page 25 6 4 Troubleshooting Trouble Remedy No weld output unit completely inop erative pilot light PL1 off Place line disconnect device in On position see Section 4 14 Check for open line fuse s and replace if open see Section 4 14 Check for proper input power connections see Section 4 14 Che
42. enir 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 tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos
43. entation 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 talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger n Ne pas toucher aux pi ces lectriques sous tension e Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip 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 u
44. eplacement Parts Model and serial number required when ordering parts from your local distributor OM 2252 Page 31 5 Hardware is common and 19 F Hardware is common and not available unless listed not available unless listed 803 897 G Figure 8 2 Panel Front With Components OM 2252 Page 32 Item Dia Par No Mkgs No i PON REN 204143 2 POS 181 245 8 C4 5 230 729 PAT Monde 010 381 Dire 161 303 6 NEG 181 246 212318 ui MD 217865 coe RM 179563 es Qu amiens 160 935 249 25 172 587 11 81 159 039 MUTA LET PLG 9 185 626 174 991 Eric 229 448 T4 s 218 080 AD eue 190 512 16 PC2 235 035 16 PC2 237 206 T PLG2 115 091 S182 rss 211 149 19 CB1 2 093995 20 RC15 604 176 lesions 229 500 RC14 143976 MOD 1 227590 Loci ire ds PLG1 200952 06 7 136735 SR C8 080 894 010494 OSE cec odis 218352 24 HD1 168 829 Sb E iat 170394 2280672 Hed OU tor 227980 r28 uote 222799 29 229 455 CONNECTOR RECTIFIER CLIP SPRING COVER OUTPUT STUD GENERIC SWITCH ROCKER SPDT 15A 125VAC ON NONE ON ILLUM CONN BODY 56 SERIES 5 FEMALE TERMINALS KNOB POINTER 1 250 DIA X 250 ID W SPRING CLIP 21 NAMEPLATE PANEL FRONT UPPER STAND OFF NO 6 32 X 640 LG 250 HEX AL FEM CIRCUIT CARD ASSY
45. es 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 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 P Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil P Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la Sortie Le circuit d alim
46. event burns OM 2252 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 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 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays tha
47. ications 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 portant 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
48. ing a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2252 Page 36 Notes Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual 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 Appleton Wisconsin warrants to its original retail purchaser
49. ion circuitry located on the secondary heat sink of the unit If this dis play is shown contact a Factory Authorized Service I mM ae mM V A Agent 3 5 Help 5 Display Indicates the secondary heat sink of the unit has over E L P 3 heated The unit has shut down to allow the fan to cool it see Section 4 2 Operation will continue when the unit has cooled 6 Help 6 Display This is a two stage error The warning stage occurs 4 when the primary voltage drops more than 1296 below the linked primary voltage setting for more than 30 sec H E L P 4 onds The display flashes a HELP 6 message during idle but the welder continues to operate normally Once the primary voltage returns to less than 10 below the linked primary voltage setting the flashing error ceases The shutdown stage occurs when the primary voltage drops more than 20 below the linked primary voltage setting for more than 30 seconds A constant HELP 6 message is displayed and weld output is disabled Once P 5 the primary voltage returns to less than 1096 below the linked primary voltage setting the constant error mes sage ceases and weld output is enabled lt gt T Mmi ak NOTE Operating the welder out of the normal operating range 12 of the linked primary will affect the output and reliability of the welder and is not recommended 7 Help 7 Display This is a two stage error The warning stage occurs wh
50. l Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output ter minal Slide weld cable terminal onto weld RON S 0007 E 4 9 Connecting Weld Output Cables gt Do not place anything between weid cable terminal M and copper bar Tools Needed 3 e 3 4 in 19 mm 803 778 B Incorrect Installation output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean OM 2252 Page 18 4 10 Remote 14 Receptacle Information A revo u Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circuit breaker CB2 OUTPUT E CONTACTOR B Contact closure to A completes 24 volts ac contactor control circuit 115 VOLTS AC l 115 volts ac Protected by circuit breaker CB1 OUTPUT CONTACTOR J Contact closure to completes 115 volts ac contactor control circuit C Output to remote control 10 volts dc in MIG mode REMOTE D Remote control circuit common OUTPUT CONTROL E 0 to 10 volts dc input command signal from remote control M Remote mode select AN F Current feedback 1 volt dc per 100 amperes AMPERAGE VOLTAGE H Voltage feedback 1 volt dc per 10 arc volts G Circuit common f
51. l welding amperage When set to max control in creases short circuit amperage at low arc 229 448 A voltage This allows the operator to use a very short arc length without sticking the electrode As control is adjusted the amount of Dig selected is displayed on the amps me ter as a percentage 0 to 10096 of full range and iG is displayed on the volts meter When Air Carbon Arc mode is selected Dig is internally set to max Control adjusts inductance when MIG or V Sense Feeder position is selected on mode Switch Inductance determines the wetness of the weld puddle As setting is increased to wards maximum wetness puddle fluidity increases As control is adjusted the amount of inductance selected is displayed on the amps meter as a percentage 0 to 100 of full range and is displayed on the volts meter This control is not functional when one of the TIG modes is selected Change control application setting to best suite OM 2252 Page 22 5 2 Meter Functions For CC CV Models 3 The meters display the actual weld output values for approximately three seconds after the arc is broken Mode Meter Reading At Idle V A Q Scratch Start TIG 78 0 85 Actual Volts OCV Preset Amps V A V rA Lift Arc TIG 5 GTAW 8 0 85 Actual Volts Preset Amps V A Ax Air Carbon Arc 78 0 85 Actual Volts OCV Preset Amps
52. lays 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 costs of any kind will be allowed TO THE EXTE
53. le x ee oe PE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 late it oath sited E be acne er he des aU 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Information EMF eer Rx E aeu uk rc e a e RE E e 9 SECTION S S DEFINITIONS miennes eee RR ix xx 11 3 1 General Precautionary Label 0 0 0 0 cece dette hs 11 3 2 Input Connection Label ierra et eR Eee ea wenn Got QURE e 12 3 3 Electric Shock And Airflow Label 12 3 4 Nameplate Safety Symbols 12 SECTION 4 INSTALLATION voi dare etek chee cee edd eee nee eee ean eines 13 41 Specifications ces vr tna ments ocre do ERU CUR EGO 13 4 2 Duty Cycle And Overheating 0 cette hs 13 4 3 Molt Ampere CUrves sse er wade pa qu Sean Xa S EX ea OUTRE CO DE Io 14 4 4 Selecting reser enr XO CUR YOUR 15 4 5 Dimensions And Weights
54. ll Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill n 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 o
55. n 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 F Indique des instructions sp cifiques e 2 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 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 alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste 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
56. nt 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 9 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 OM 2252 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 S
57. of weld cable see Section 4 8 Clean and tighten all weld connections Check wire feeder installation according to Owner s Manual Check position of Mode switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 front panel display board PC2 and hall device HD1 No 115 volts AC output at duplex re ceptacle or Remote 14 receptacle Reset circuit breaker CB1 see Section 4 7 No 24 volts AC output at Remote 14 receptacle Reset circuit breaker CB2 see Section 4 7 Fan not operating Note fan only runs when cooling is necessary Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc poor control of arc di rection Reduce gas flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten Check for water in torch and repair torch if necessary See torch Owner s Manual Digital meter not working properly Have Factory Authorized Service Agent check front panel display board PC2 and connections and re place if necessary OM 2252 Page 26 Notes
58. oints and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 1 8 179 563 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring and exposed weld terminals can kill Close door before turning on unit 3 4 Nameplate Safety Symbols IB 5 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 OM 2252 Page 12 SECTION 4 INSTALLATION 4 1 Specifications Rated Amperes Input at Rated Load Output 50 60 Hz Model Welding amperage Max ocv pc Thres Phase Output oltage Range 230 V 380 V 400 V 440V 460V 575 V KVA KW 78 VDC In CC Mode For 5 500A In CC 60 Hz Mode d 80 VDC In CC 450 A 38 Mode For 5
59. oper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage stor vq E UTE WE eat 1 122 Arc Welding Hazards rtt rre oes ed Pa Rea aos d puce c ISSUE Set 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 2 4 1 5 Principal Safety Standards 2 4 1 6 EMFnformation sis rm px ER OE alls Saa
60. or 24 and 115 volts ac circuits GND K Chassis common The remaining sockets are not used 4 11 Connecting Remote Control Per 1 A Turn off power before con necting to Remote 14 recep tacle Remote 14 Receptacle RC14 Connect remote control to RC14 Ne o cd Ref 800 166 D Ref S 0004 A S 0750 OM 2252 Page 19 4 12 Electrical Service Guide A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 50 60 Hertz Models Input Voltage 230 380 400 440 460 575 Input Amperes At Rated Output 57 34 33 30 29 23 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 70 40 40 35 35 25 Normal Operating 3 90 50 50 45 40 35 Min Input Conductor Size In AWG 4 6 8 8 10 10 10 Max Recommended Input Conductor Length In Feet Meters 145 44 256 78 284 86 226 69 243 74 380 116 Min Grounding Conductor Size In AWG 4 8 10 10 10 10 10 Reference 2005 National Electrical Code NEC 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses ar
61. ordering parts from your local distributor OM 2252 Page 33 F Hardware is common and not available unless listed 803 937 C Figure 8 3 IGBT Capacitor Assembly OM 2252 Page 34 Item Dia Part No Mkgs No Description Quantity 221 298 Figure 8 3 IGBT Capacitor Assembly Fig 8 1 item 23 221301 BUS PLATE IGBT TO CAPACITOR NEGATIVE 1 ix uaa RS 221304 STAND OFF CONDUCTIVE BUS 5 Ng IP 221 303 INSULATOR BUS PLATE 0 0 ccc ccc cect eee 1 Ae tae thas ae 221300 BUS PLATE IGBT TO CAPACITOR POSITIVE 1 5 R8 188067 RESISTOR WW FXD 100 W 200 OHM W CLIPS 1 221299 TRAY MOUNTING COMPONENTS 1 race 010 494 BUSHING SNAP IN NYL 1 375 ID X 1 750 MTG HOLE 2 ESR Ol 224144 BUS BAR IGBT OUTPUT W FINS 1 se ET 223387 ASSY HEAT SINK 600A IGBT 1 10 TH2 188 431 THERMISTOR NTC 30K OHM 25 DEG C 27IN LEAD 1 pena cae 010546 BUSHING SNAP IN 375 ID X 500 MTG HOLE 1 12 01 222654 CAPACITOR ELCTLT 35000 UF 100 VDC CAN 3 00DIA STUDMNT 3 ex edes 222653 BRACKET MTG CAPACITOR 8 1 14
62. 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 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 c bles de sou dage causera des champs lectromagn tiques y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites
63. r accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Indicates special instructions 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 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 Keep cords dry free of oil and grease and protected from hot metal and sparks 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
64. r 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 o LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l
65. rcuits 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 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 pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de
66. rk and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 2252 Page 11 3 2 Input Connection Label 1 96 1 2 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection p
67. t 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 Z49 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 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 bulkh
68. tistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent 9 provoquer des blessures gt Qi e Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 2252 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 geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures AJ 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 rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser 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 maint
69. u 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 2252 Page 5 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 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 D LES FUM ES ET LES GAZ peuvent tre dangereux I Le soudage g n re des 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 et ou 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 cif

Miller Electric Dimension NT 450 User's Manual

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