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Miller Electric Dimension 1000 User's Manual

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1. 1 E erties lanae wid ete ad feat 193 676 TERMINAL ASSY primary 3phase 1 EN C EE CR4 4140 750 SWITCH feed unica eg oe ee xc e wa e 1 o fecit Wii 193 473 CONTACTOR size 3 1 2 3P 24VAC 1 jud OF O ads 217 136 LABEL warning electric shock mo 2 A 193 462 BRACKET contactor mount 1 E NERONE 11635399 BASE nci sek gu ERE ERES E etd Ue he sube Swe 1 PN PET Lt P 218414 TRANSFORMER pwr main 230 460 575 1 OD O TP1 2 175405 THERMOSTAT NC Included w T1 2 E RE TP45 168891 THERMOSTAT NC Included w T1 fan control circuit 2 TRU PEG 1 168847 CONNECTOR amp SOCKETS 1 Rs rene RC6 xus 168 945 CONNECTOR amp PINS 33 0252 Lohnt Uem dun etes 1 Hein PLG13 218413 HOUSING plug pin skt service kit 1 EE RC13 218408 HOUSING plug pin skt service kit 1 A dap as ode tees 161 294 BRACKET mtg rechter 2 E I EU Ed Figure 8 2 PANEL front w components 1 Noo A SAL Des 191 257 RECTIFIER scr main Figure 8 3 naaa anannnn 1 Ne dr ae PLG7 152 249 CONNECTOR amp PINS l En RC7 168846 CONNECTOR A SOCKETS T T 010 467
2. l dus tds CRI 32 052 964 RELAY end 24VDC DPDT 1 D sale CRS Coon 006 393 RELAY end 24VAC DPDT 1 T m CB12 ias 093 995 SUPPLEMENTARY PROTECTOR man reset 1P 15A 250VAC 2 NE T RC9 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 wp rr 191 335 RECEPTACLE CAPACITOR w leads includes 1 TEE RC8 143 976 RCPT w SCKTS service kit 1 DEE C3 6 13 14 097 749 CAPACITOR cer disc 05 uf 500 VDC strip 4 S XD RETE 190 959 PANEL front aos dee nee oe x bee ere 1 s ONDES C2 4 5 230 729 CAPACITOR cer disc 1uf 500VDC w terms 3 E KEE 190 961 TERMINAL single stud 1 cru TT 190 960 TERMINAL double stud 2 eeh R4 5 136 076 RESISTOR WW fxd 30W 200 ohm 2 pcm E 161 303 SPRING cprsn 600 OD x 072 wire x 1 500 lg 3 A hate EE SC 234 313 PLATE control lower 1 52 9g ee e ewe C eet te e x oec s 1 AAA TE es dens 159 040 BLOCK term 20A 12P sii o RR er ed Bt xe 1 Miss ER ee ce are ae 162 828 PANEL mtg rcpt terminal strip 1 OM 2223 Page 32 ltem Dia Part No Mkgs No Description Quantity Figure 8 2 Panel Front w Components Figure 8 1 Item 32 Continued apre
3. CONNECTOR clamp cable 1 250 1 LOU alee ation OM actua E 604 536 SCREW 312 18 x 1 75 hex hd pln gr5 pld 2 Tc PEE C20 R20 200 595 MODULE capacitor resistor 10 mfd 250 vac 1 Part of Option 195 048 Ground Current Sensor Optional When ordering a component originally displaying a precautionary label the label should also be ordered Hecommended Spare Parts 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 2223 Page 31 ICS Hardware is common and not available unless listed 802 297 Figure 8 2 Panel Front w Components Figure 8 1 Item 32 ltem Dia Part No Mkgs No Description Quantity Figure 8 2 Panel Front w Components Figure 8 1 Item 32 ET TET 159 863 ELECTRONICS BOX ics dee d d Ed eee dece Ete se te 1 Sy Ee PGT 5s 207 034 CIRCUIT CARD ASSY control 0 0 0 ce eee 1 o E POL ou 223 767 CIRCUIT CARD ASSY control low OCV nananana annann 1 G ee PLG1 158720 CONNECTOR amp SOCKETS see Figure 8 3 TH PLOS 169240 CONNECTOR amp SOCKETS cbe oia de TCR PLG4 148439 CONNECTOR amp SOCKETS e 1 TERMES PLGS 152 249 CONNECTOR amp SOCKETS 15 xe ER E acera d PRIM PLG16 158719 CONNECTOR amp SOCKETS
4. OM 2223 190 969AC m 2007 11 Miller O PR Multiprocess Weldin i Description a 2 EJ Arc Welding Power Source Dimension 1000 OWNER S MANUAL File Multiprocess Ga Visit our website at 9 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 Ir Y E BL El Her 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 TRE ete jue ere ex e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And if for some reason the unit ne
5. entra ner 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 piece est sous tension lorsque le courant est d livr 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 talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de maniere incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e 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 Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suiv
6. 2 2 Dangers relatifs au soudage l arc 2 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 s Goan ae doe aus tale mes Sco X dont wR as 9 2 6 Information EME 424 cain devas doe ele ER Giana A A NE ero ge ue whe 9 SECTION 3 DEFINITIONS anes eet ees rnm ERI PE EE IEEE T ce RE RU OR Race Nue bee Gano uate e 11 Sra ME ence Bie REC x is rrr 11 SECTION 4 INSTALLATION fit verte reae quo e erue ee dca eh uro a EE me Rap E Rud act teens tendered 11 4 lu sere LETT 11 4 2 Duty Cycle And Ovethealllg s enean ex e dete e ese ates p aeuum aesti 12 4 3 Molt Ampere QUIVOS ida x PRECOR ee MES SEER E SEPT RE IY EA 13 4 4 Selecting A Location ra HERE ERE RADA DATA AAA AAA AS ARA 14 4 5 Dimensions And WeIGMS sa AS A AAA e 15 4 6 Kin ell Le WEE 16 4 7 115 VAC Receptacle Supplementary Protectors And Weld Output Terminals 16 4 8 Basic Sub Arc SAW Welding 17 49 Selecting Cable Ses ENEE 21 4 10 Remote 14 Receptacle And Terminal Strip 1T Information 21 4 11 Connecting Remote Control 22 4 12 Electrical Service Guide 4 6 cir ea a ed ea eed ase ee ee eed a eee wae dvs we RON RR nas aw S 23 42213 Placirig Jurmper
7. Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 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 2223 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 a
8. QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande m OM 2223 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette 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 qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e 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 tiliser que les pi ces de rechange recom mand es
9. and flux system for the desired application A Basic Sub Arc SAW Equipment Connections 6 A Turn off welding power som E source and weld control and disconnect input power be fore making connections Use remote voltage sense leads in all applications 7 Suggested size for remote volt age sense wire is 12 gauge or larger gt For better performance for most Sub Arc SAW applica tions make connections to the Submerged Arc weld output terminal CS Polarity For DCEP Reverse Polarity connect weld cables and voltage sense leads as shown For DCEN Straight Polarity reverse weld cables and voltage sense leads C E D J A P K M L Remote 115 VAC 24 VAC Remote GND_ Remote Contactor Remote Remote Voltage Power On Off Control Contactor Contactor Sense 3 162 895 B FLUX SYSTEM HDC Controller OY 14 Pin Welding Power Source Control Cord E 9 2 10 Pin Motor Control Cord Dimension 1000 1250 From Terminal o Strip TT Terminal P From Terminal Strip 1T Terminal N N Submerged Arc Weld Cables Ref 805 007 A OM 2223 Page 17 B Control Settings For Sub Arc SAW Welding SMAW DIG E d PLN Bee ARC FORCE PROCESS G AN ON PANEL Q REMO OUTPUT CONTROL Turn on welding power source flux system wire drive assembly and HDC Sub Arc controller When Control switch is in Remote
10. dage causera des champs lectromagn tiques II 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 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 sit
11. 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 toa 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 IMPORTANT Conductor 5 Reed Switch Ground Current 6 Input Terminal Board Sensor Optional Connect green or green yellow grounding 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
12. ou autres probl mes de procr ation Pour les moteurs diesel 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 249 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
13. 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 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 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 0 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 900 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 4 4 0 4 4 0 1000 2 2 0 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 1250 2 3 0 2 4 0 3 3 0 4 3 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 S 0007 E 4 10 Remote 14 Receptacle And Terminal Strip 1T Information Socket Terminal Information OUTPUT A A 24 volts ac Protected by circuit breaker CB2 24 VOLTS AC CONTACTOR B B Contact closure to A completes 24 volts ac contactor control circuit C C Command reference 0 to 10 volts dc CC 10 volts dc CV REMOTE OUTPUT CONTROL D D Remote control circuit common E E 0 to 10 volts dc input command signal from remote control A V AMPERAGE F dc Current feedback 0 to 10 volts dc 1 volt per 100 amperes VOLTAGE H Voltage feedback 0 to 10 volts dc 1 volt per 10 arc volts MEMOS AG OUTPUT l l 115 volts 15 amperes 60 Hz ac Protected by circuit breaker CB1 CONTACTOR J J Contact closure to completes 115
14. 966 mm Including strain relief D 35 in 889 mm E 1 1 4 in 32 mm F 21 1 8 in 537 mm G 1 1 8 in 29 mm H 7 16 in 11 mm Dia Weight 1000 Amp Models 644 Ib 292 kg OM 2223 Page 15 4 6 Tipping A Do not move or operate unit where it could tip 4 7 115 VAC Receptacle Supplementary Protectors And Weld Output Terminals A Turn Off power before connectingto receptacle or weld output terminals 115 V 15 AAC Receptacle RC9 Power is shared between RC9 Re mote 14 receptacle RC8 and termi nal strip 1T see Section 4 11 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 115 volts ac portion of RC8 1T and RC9 from overload CB2 protects 24 volts ac portion of RC8 and 1T from overload Press button to reset protector 4 Positive High Inductance Submerged Arc Weld Output Terminal Use this terminal for Submerged Arc SAW TIG GTAW scratch start only or Stick GMAW applica tions 5 Positive Low Inductance Weld output terminal Not recommended for Submerged Arc applications 6 Negative Weld Output Terminal Connect work cable to this terminal for Submerged Arc applications Ref 802 295 OM 2223 Page 16 4 8 Basic Sub Arc SAW Welding CS Customer must supply the following power source power source control cable wire drive assembly wire drive assembly cable drive rolls gun welding wire weld cables remote voltage sense leads
15. 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 FLYING SPARKS can cause injury 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 e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards IN dei 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 3 STATIC ESD can damage PC boards 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 d Ki 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 READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from t
16. CPP 070 371 BLANK snap in nyl 1 093 1 125mtg hole 1 T bide sti tee Du 217 865 LABEL warning electric shock and reduced air 1 j CEN IPTE E 172587 COVER output stud 1 CO tee ia 160 935 CLIP SORA botines etes dio eee iet ded draco avare aera 3 D EE 601 835 24 NUT 10 32 DIS tonos Liu dede isaac ica 2 TE 010 913 WASHER flat 218 ID brs d NL Sei A Ae ER 185 011 STUD pri bd brs 10 32 x 1 592 1 OD UM Oil tere 088 409 SWITCH tgl DPDT 15A 125VAC On Off On 1 a EE DO adi ie 011 609 SWITCH tgl SPDT 15A 125VAC On None On 1 pia PE TE Hl aia 198 087 POTENTIOMETER CP std slot 1 T 2W 1K ohm 2 REO erate ee 2 sino 232 116 CIRCUIT CARD ASSY display w program 1 TNR HE PLG10 153501 CONNECTOR amp SOCKETS 1 DOT PLG11 148439 CONNECTOR A SOCKETS 7 Lr EEN OR2 s 116 592 RELAY encl 24VDC 2pDT anan na nrnna 1 DE nuni ups EE ee 192 174 2 STAND OFF on bee ie ERE EX Seng d ER SESS e RE Skee 4 ES E N lls Bead aan 193 704 2 PANEL TrOntUpDer 1152 ewe Sa re a Dee bee ne R s 1 RE NAMEPLATE order by model and serial number 1 JOD SE o EE 159 039 SWITCH rocker SPDT 15A 125VAC 1 p
17. 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 Tools Needed 10 Disconnect Device Line Terminals e 38 81 Connect input conductors L1 U L2 V And L3 W to disconnect device line C dU 38in terminals 11 Overcurrent Protection E Y 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 11 16 in Ref 800 103 C Ref 802 295 OM 2223 Page 24 SECTION 5 OPERATION Controls 5 1 1 Arc Force Dig Control Control increases SMAW short circuit amperage which allows the operator to use a very short arc length without sticking the electrode Set control at 0 for normal welding amper age Turn clockwise to increase short circuit amperage 2 Process Selector Switch e Sub Arc Mode For SAW Sub Arc ap plications NOTE Use the High Induc tance Submerged Arc terminal e CC Mode For SMAW Stick GTAW TIG scratch start only or SAW Sub Arc applications NOTE For best results use the Positive High Inductance Sub merged Arc weld output terminal e CV Mode For FCAW Flux Cored ap plications CC CV DC Welding Power S
18. 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_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 Num
19. 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 Owners Manual and national state and local codes 7 Indicates special instructions e P ei 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 cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding c
20. 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 2223 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coupe l alimentation e 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 b LES FUM ES ET LES GAZ peuvent tre dangereux A N 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 l int rieur ventiler la zone et o
21. par le constructeur e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une 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 Le rayonnement haute fr quence H E 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 l
22. position Adjust control does not function Set desired preset voltage on Sub Arc controller Preset voltage is displayed on weld ing power source voltmeter A V ADJUST OM 2223 Page 18 C Remote Voltage Sensing Leads Placement Guidelines For A Single Arc Required Ae PAGA Remote Voltage Sense Leads n Welding Power one Source Sense lead is affected by weld current Due to voltage drops across work piece arc voltage may be low causing need for deviation from standard procedures Work Clamp Remote Voltage Sense Leads N Welding Power BEST TEE Source Sense leads are out of the current paths Sense leads detect arc voltage ac curately Best starts arcs and most reliable results Work Clamp Ref 804 108 A OM 2223 Page 19 D Sensing Leads Placement Guidelines For Multiple Arcs WR Remote Voltage Sense Leads Lead NA Welding Power Source Remote Voltage Sense Leads Welding Power Source Lead Welding Power Source Remote Voltage Sense Leads Lead Remote Voltage Sense Leads Welding Power Source ml SH LO uU CET Mog Remote Voltage Sense Leads Head A Welding Power Source C Remote Voltage Y RC Sense Lead My NP ense Leads X7 Lead Trail Trail P aft 4 Welding Power Source a TU J L E OM 2223 Page 20 BAD Current flow from lead affects trail sense Current flow f
23. replace if necessary OM 2223 Page 27 SECTION 7 ELECTRICAL DIAGRAM AA WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit 975N GROUND CURRENT Q SENSE OPTION 230V E TE L LL U d Y L Yi L RC13 RC6 FLD DLG PLEG amp i 32V D a B ZK 47 KEIER v sl D e o RC1 1 gt RC1 10 gt PCI CONTROL BOARD RC1 PLG1 RES PLES RC3 PLGS RC6 PLG16 RC4 PLGA amp RCI BY S L N G a MN do N ls NON T RC1 5 gt E RC1 42 gt RG1 4 gt R 3 gt RC1 2 gt RCI 7 gt RC1 A gt RCI 9 gt Q S RC3 15 aT Gen 13 Tye A Cc E D tr C X GC a c uc DC Y VYN N M M M N V V V V 4 43 42 KS O 47 4 BEEN CBI EB NEN PTS lt 11 AME MM eerste A 42 REO HS 3 7 3 Q MT S S ON BR GR SIL S2 Oy 15 E PA 10 WILK T PLI IS B IN SZ 5 Co i S ae AC VEL S mew CRA SS BE el S ARG FORCE 17 O S E CONTROL TRANS T TPS CR4 E USED WITH RECT GROUND CURRENT SENSOR OFTION 73 9 a TRANS RC amp t K GA I B Figure 7 1 Circuit Diagram OM 2223 Page 28 NOT USED W LOW CGV OPTION Ee ARC y HIGH INDUCTANCE ZE y et a0 LOW T INDUCTANCE O AF K CD A L L T PRESI ON doi iR N O uU o o RC4 1 277 K Ru 10 1 py LA G 5
24. see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away PE ao ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do nottouch 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 output is required use remote output control if present on unit e Additional safety precautions are required when any of the
25. 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 749 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 Es 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
26. 223 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 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 ihs 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 Informa
27. Check position of Remote Amperage Voltage Control switch see Section 5 1 Erratic or improper weld output Use proper size and type of weld cable see Section 4 9 Clean and tighten all weld connections Check wire feeder installation according to Owner s Manual Check position of Process selector switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 and hall device HD1 No 115 volts ac output at duplex recep tacle Remote 14 receptacle or terminal strip 1T Reset circuit breaker CB1 see Section 4 7 No 24 volts ac output at Remote 14 re ceptacle or terminal strip 1T 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 direction 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 control board PC1 and connections and
28. LINKS anserum eco coe vce wis ae eatery eee eee ele Se ee ee Pe tee ed ee ee 23 4 14 Gonnecting Input e iis duce ecce cae OR C t C aa ce Rae eee OE e cue Ea ae EE oes 24 SECTION 5 OPERATION 06 tive dees A EEN 25 5 1 GONTO S danita etn dona ce ace LE ru dio eh ba aeu eh bd ae ee SE 25 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 26 6 1 Routine Mantenan oux aieo he em ee E rf ex p ate acr aud ao een dd sas dd er seuss 26 02r EUSO A E T E E E E A 26 623 FfOUDIGSHOOING 3 4 ae iced Soe teat ey E et Aa 27 SECTION 7 ELECTRICAL DIAGRAM soon AAA 28 SECTION PARIS BIST ach cata cate ee Ea ie a de Mato adrien a eee ewe eae eee aes 30 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 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 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you
29. Lu 2 a pel ul DUTY CYCLE 100 Duty Cycle D Continuous Welding Overheating Joa 0 A V gt e gt Dd gt Minutes Reduce Duty Cycle duty 4 95 SA 191 157 B OM 2223 Page 12 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 A CC Mode tween curves shown 70 VOLTS 200 400 600 800 1000 1200 1400 1600 AMPERES B CV Mode 80 70 60 50 40 Volts 30 20 10 100 200 300 400 500 600 700 800 900 1000 o Amperes va curve1 4 95 ST 199 986 A ST 190 973 OM 2223 Page 13 4 4 Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit Movement If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Use rating label to determine input power needs Label located under front access door 4 Line Disconnect Device Locate unit near correct input pow er supply A Special installation may be Location And Airflow required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 INPUT SERIAL NO STOCK NO VOLTS AMPERES KW PHASE OM 2223 Page 14 4 5 Dimensions And Weights 4 Holes 800 453 A 801 530 Dimensions A 30 in 762 mm Including lift eye B 23 in 584 mm C 38 in
30. antes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles 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 EF Indique des instructions sp cifiques 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 cord
31. ber 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 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 GQ Miller
32. 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 Tenir les 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 Lecouvercle 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 inflammab
33. commended Input Conductor Length In Feet Meters c 337 103 438 134 Min Grounding Conductor Size In AWG 4 4 6 6 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 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 13 Placing Jumper Links 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 only one is on unit 2 Jumper Link Move jumper links to match input voltage and label on unit Close and secure access door or go on to Section 4 14 193 526 m G om SER 230 VOLTS AMIA lt lt 460 VOLTS ef o 1 575 m oooofif Do not overtighten jumper link nuts Tools Needed C FAO 3 8 in Ref 802 295 OM 2223 Page 23 4 14 Connecting Input Power A Installation must meet all National and Local Codes have only quali
34. ctifier o es ane Re ne add 1 TOR TP6 168894 THERMOSTAT rectifier fan control circuit 1 ICS Hardware is common and not available unless listed 800 696 A Figure 8 3 Rectifier SCR Main 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 2223 Page 34 No Mkgs No Description Quantity Figure 8 4 Panel Rear w Components Figure 8 1 Item 21 TTE RETE 132 101 CHAMBER plenum 14 in motor mount naana annann 1 TL eC ae 605 799 BLADE fan 14 in 5wg 30deg 500 bore CW 1 G HO de r 191 5952 Lc PANEL Taiana lie duces Iu ertt etai cbe elt 1 Dae dba na 168 343 HINGE door primary sra ic oe RR Rm e es 2 crier lt Auge 191 553 e DOOR primary Tee 44228 28 ee VERS e bdo e ce Rn ot 1 Tp ev 217 733 LABEL warning electric shock amp input power EN FR 1 Cvm SS EE 097 459 RESISTOR WW fxd 375W 20 ohm for units w o low ocv 1 in Os eee FM uus 032 605 MOTOR 1 4HP 230VAC 1625RPM 50 60HZ 1 T pv m 183 167 CONNECTOR clamp cable 2 000 1 3 ICS Hardware is common and not available unless listed 802 298 C Figure 8 4 Panel Rear w Components When ordering a component originally displaying a precautionary label the
35. e 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 cables ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les cables 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 2223 Page 9 Notes D Work like a Pro Pros weld and cut A Nt safely Read the E safety rules at NN the beginning of this manual OM 2223 Page 10 SECTION 3 DEFINITIONS 3 1 Symbol Definitions Ny Alternating Current Panel Local Li
36. e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e 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 SET 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 elle
37. e REIO 4 O S bod RO4 4 EI F RC4 TE lt RCI1 5 RC4 5 227 REI 1 2 RC4 gt gt lt RCI 1 8 BREI RC4 o gt X RZI1 9 CE RC4 pP RSI 1 E RTE E E WA ROO 2 2 oe ae b d EL ds r E E z DB 88 S NN a NV AAA AST 73174 ze zie 47 V JA 48 46 6 VAS O CRZ CRZ G PUTA SAT LO er nn Se IN A a MS A SNS a LJ By G lt A LJ a DE 7 i oV PLG7 vm 776 43 11 IF IR4 27 28 43 3 Q RC7 9 DD O0 D D DD S E D d FNP KML REMOTE NZ REMOTE d s S OUTPUT Caisse GND POWER AMP VOLT P CONTROL CONTACTOR ON GFF CONTROL 113VAC REMOTE CW REMOTE VOLTAGE CONTACTOR SENSE 43 O 76 ZZ 47 1 7 T I I RCB D E C F H N 236 682 A OM 2223 Page 29 SECTION 8 PARTS LIST ICS Hardware is common and not available unless listed d SE ST A a Rom GNX V 27 J ZE LENS 3 S S aS as N his R N di Figure 8 1 Main Assembly OM 2223 Page 30 No Mkgs No Description Quantity 8 1 Main Assembly b xb gerado WN sce Bod ade Bh s 1179432 12 PANEL e asar Sic bea eet ae She bee o polis See d diss he 2 TE eee ee 179431 go COVER Ee DEE 1 E A A See 164 700 BAFFLE Air dar tai 2 RH os oa ascents 162 816 CHANNEL upright front 2 ENTRE es tie ard a ete E 191 285 5 GUSSET ASSY uisa quado eer pese EE 2 e EEN 162 820 BAR mtg lift eye 2 OR eee ee EST 177 279 CASKET IN OyO senda ae ose ta conia a ra ocn i e di
38. ecu E PLA eects 159522 LED VelOW zoe eh tr ot heat o into b 1 cc T 159 036 LENS LED clear beet tee dia 1 A E Pis EEEN 097 924 KNOB pointer 1 EE 097 922 KNOB e e Un EE 1 SOW hid ag edi i das aad 197 S66 4 SNUBBER SSV 39543 0 94 ee a 1 36 Luv iua Od Loaded 011 611 SWITCH tgl DPDT 15A 125VAC On None On 1 Optional When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2223 Page 33 ltem Dia Part No Mkgs No Description Quantity Figure 8 3 Rectifier SCR Main Figure 8 1 Item 33 1 C7 12 048 420 CAPACITOR cer disc 01uf 1000VDC ooooooooooooo o 6 K ee eee 176168 BAR mtg rechter 2 E EE 166 667 CLAMP spring thyristor rectifier 3 TU ER 191 248 HEAT SINK rectifier snowflake1 500 6 5 SCH1 6 148091 THYRISTOR SCR 865A 300V hockey pouck annarra 6 mp Dr 191247 HEAT SINK rectifier snowflake3 000 3 ETE PE TITRE 191246 CLAMP thyristor rectifier 8 187 3 EE PEGA 222 158120 x CONNECTOR amp SOCKETS iss REA TRAE RS aa 1 C TPS subis 192 731 THERMOSTAT re
39. ed 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 Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR
40. eds 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 EGN oA a aaa 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 C Miller Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MPSS e O RC RR Rae ae ee hae Ren li db ane een Edere er La 1 152 Are Welding e EE 1 1 3 Additional Symbols For Installation Operation And Maintenance eens 3 1 4 California Proposition 65 Warnings ete eee eee 4 5s P ncipal Satety Standards es curn deo pated eee ieee jie fast e de te sarta Dan So maa Da a 4 156 EME Tee x nene rita d i Dar ti a Sinker n c acr d o Dot a a bd ed DAC Ee V d is 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS TEEN 5
41. eplace 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 ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Fl
42. es 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 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 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A 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 2223 Page 8 Pour les moteurs essence 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
43. he 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 Theuseris 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 Toreduce 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 lf 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 2
44. its 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 oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 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 HE FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e
45. 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 2223 Page 35 Notes Notes Notes 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 GQ 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 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 r
46. les e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est 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 L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures EN e Porter un cran facial pour prot ger le visage el 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 e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable P Q S a LES CHARGES ELECTROSTATI
47. nd 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 securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circu
48. ne Connection Direct Current DC Three Phase Rated No Load Rated Supply POCO Voltage Average Voltage Circuit Breaker Rated Maximum Supply Current Conventional Load Rated Welding Protective Earth Voltage Current Ground 3 Phase Power Source With Temperature AC DC Output Maximum Effective Ventilating And Air Supply Current Circulating Fan Submerged Arc Read Operator s ATAR O O Degree Of Air Carbon Arc Shielding Metal Arc Protection Cutting CAC A Welding SMAW Gas Metal Arc Welding GMAW SECTION 4 INSTALLATION 4 1 Specifications Amperes Input at Rated Load e Output Rated Welding Amperage Voltage Max Model Output Range DC OCV DC 60 Hz Three Phase 230 V 460 V 575 V KVA KW 100 1250 A In CC 1000 A 44 Mode 180 90 72 73 53 1000 Amp Volts DC 100 66 VDC D I 2 9 2 4 3 2 0 5 Duty Cycle 10 60 V In CV Mode While idling Open circuit voltage is 26 volts dc if unit is equipped with optional low open circuit voltage OM 2223 Page 11 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min AAA HE AE A BH 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 e OI Or
49. ode 1 EE hee ducatu cedo de t 162 890 BIET EYE uds aede y eene di eerte doe i det cer bemus e se end 1 Seda ip Seale dus tet ie baie 604 536 SCREW 312 18 x 1 750hexhd gr5 2 TE QT DUMP 134 201 STAND OFF SUPPORT pc card 4 ix dO TT 162 821 BRACKET mig LEM 3222 d hw do EH aed Corset 1 ee HD1 148 417 TRANSDUCER current 1000A module 1 S PLG14 180204 HOUSING PLUG PINS amp SKTS d A de cu a a 191 213 BUS BAR stabilizer oae em En Bae ee Es 1 Wo T 7 MP 1909540 STABILIZER sra tace edo ac brenda a 1 a roD C21 23 is 099518 SGAPAGIT ORS cu ia Isa Tun aan ae men Seats acto tow epe A PO esos 3 udo Leu dac AA 226 704 XFMR control 110VA 24V 230 460 575 DH 1 so LS A TET uds 193 495 PRIMARY BOX includes 1 SN rr cre Tt es tee 601 835 ace NUT 10 32 DIS 35249 Ded args HO a ee ee eS 24 EQ EE 038 887 STUD pri bd brs 10 832 X 1 375 WEE 24 idt Walesa date arse di pace ars 038 618 LINK jumper term bd pri 8 esa ees ee 010913 WASHER flat 218 ID brs 24 STT 601 835 lt 5 NUT 10 32 lt T 24 A asie 159034 HOLDER f se MINT 2 is ec et 1 E AECH m Bosca 156 065 FUSE crtg 5A 600V time delay anaana a nanan 1 DEC MI ee ee ee Figure 8 4 PANEL rear w components
50. om 2007 04 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 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 l arc 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 Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil rm UNE D CHARGE LECTRIQUE peut a
51. on 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 Eneffectuant 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 utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pieces endommag es Entretenir l appareil conform menta ce manuel Porter un harnais de s curit si l
52. onduc 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 e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical 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 removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructi
53. ons 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 iiim OM 2223 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
54. ource 3 Amperage Voltage Adjustment Control When Process Selector switch is in the Constant Current position turn control clockwise to increase amperage Read am perage from outer scale of control When Process Selector switch is in the Constant Voltage position turn control clockwise to in crease voltage Voltmeter value changes as control knob is turned Control can be ad justed while welding 4 Digital Meters With Process Selector switch in the Constant Current position digital meters will read O zero with contactor off Digital me ters will display actual output voltage and amperage with contactor on With Process Selector switch in the Constant Voltage position voltmeter dis plays preset voltage with contactor off Volt meter and ammeter display actual output voltage and amperage with contactor on 5 Power Switch With Indicator Light 6 High Temperature Shutdown Light A 7 Remote Amperage Voltage Control Switch e For front panel control place switch in Panel position With Control switch in the Panel position and Process switch in the CC position Hot Start is energized for ACA Air Carbon Arc Gouging and SMAW Stick welding When Hot Start is energized higher short circuit amperage helps arc starting After arc starts the Am perage Voltage control setting determines weld amperage For remote control place switch in Re mote position and connect remote device see Section 4 11 NOTE Hot S
55. owmeter 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 4 6 Months Batteries 5 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 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 operat
56. pen See Section 4 14 Check for proper input power connections see Section 4 14 Check for proper jumper link position see Section 4 14 Check fuse F1 and replace if necessary see Section 6 2 No weld output pilot light PL1 on Unit overheated Allow unit to cool with fan On see Section 4 2 If using remote control place Output Contactor switch in Remote 14 position and connect remote control see Sections 4 10 and 4 11 If remote is not being used place switch in On position see Section 5 1 Check repair or replace remote control No weld output power switch pilot light on fan off Check for proper input power connections see Section 4 14 Check for open line fuse s and replace if open or reset circuit breaker see Section 4 14 Turn power switch off then back on If no output condition remains have Factory Authorized Service agent check SCR s Limited weld output and low open circuit voltage Check position of Remote Amperage Voltage 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 14 Clean and tighten all weld output connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1
57. rom trail affects lead sense Neither sense lead picks up the correct work voltage causing starting and welding arc instability BETTER Lead sense is only affected by weld current from lead Trail sense lead is only affected by weld current from trail Due to voltage drops across work piece arc voltage may be low causing need for deviation from standard procedures BEST Both sense leads are out of the current paths Both sense leads detect arc volt age accurately No voltage drop between lead and trail sense Best starts arcs and most reliable results Ref 804 108 A 4 9 Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding rage ON zon amon soon en son 10 60 v A 10 100 Duty Cycle poorly spliced cables 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
58. s 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 l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e 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 gerles 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
59. 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 ou 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 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 a 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 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
60. tart is not energized when switch is in the Remote position 8 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of out put place switch in Remote position and connect remote device see Section 4 11 Weld output studs are energized only when Output switch is in On position or while welding Turn Off power before connecting re mote device OM 2223 Page 25 229 883 A SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect and lockout tagout input power before per forming maintenance or troubleshooting procedures Heplace Hepair or Clean and unreadable replace tighten weld labels cracked weld terminals cable 6 Months Blow out or vacuum inside T During heavy service clean monthly rs A L p 6 2 Fuse F1 A Turn Off power before open ing rear access door 1 Fuse F1 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 Tools Needed CFO 38 in Ref 802 295 OM 2223 Page 26 6 3 Troubleshooting Trouble Remedy No weld output unit completely inoperative pilot light PL1 off Place line disconnect device in On position see Section 4 14 Check for open line fuse s and replace if o
61. tion 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 2223 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 Instit
62. u 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 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 peu
63. ute 25 West 48rd 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 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 s
64. vent 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 l 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 e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc 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 2223 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
65. volts ac contactor control circuit GND K K Chassis common G S Circuit common for 24 and 115 volts ac circuits i L REMOTE POWER ON OFF G To remote On Off switch N N Voltage sensing signal from Negative weld output terminal REMOTE VOLTAGE SENSING b P Voltage sensing signal from Positive weld output terminal Not Used OM 2223 Page 21 4 11 Connecting Remote Control A Turn off power before con necting to receptacle 1 Remote 14 Receptacle RC8 Connect remote control to RC8 If plug does not fit wire cord to terminal strip 1T A Turn Off power before open ing terminal strip cover 2 Terminal Strip 1T 3 Remote Control Cord 4 Strain Relief Customer Supplied Secure cord in strain relief Reinstall and secure access panel Close door OR OR C E Dl J AB NPKML T 76 75 32 2 4 J Ref 802 295 Ref S 0004 A S 0750 OM 2223 Page 22 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 60 Hz Input Voltage 230 460 575 Input Amperes At Rated Output 180 90 72 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 225 110 90 Normal Operating 2 250 125 110 Min Input Conductor Size In AWG 4 3 0 3 4 Max Re

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