Miller Electric Delta-Fab User's Manual
Contents
1. 4 1 6 EME Information i siente rm px ese Fuld ER OE alls RR de Saale x ee oe PE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles titiliS6S1 cultam nU NC E be N acne hans he des aU 5 2 2 Dangers relatifs au soudage l arc 5 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2 5 Principales normes de s curit 8 2 6 Information Rak ex I eee So ee hg RC REL 8 SECTION 3 INSTAELATION 1 i TEX XERERIGSESPLERRRR E DR 9 3 1 IER ep Aid Ode URN e UR daha IER P RAD RN 9 3 2 Duty Cycle And Overheating 9 3 3 Volt Ampere Curves 1 10 3 4 Selecting A REDUCE REM DRIN Ae ee aR 11 ROI A 11 3 6 Dimensions And Weights uec e hee enr er REOR DEOR en RUE 12 3 7 115 VAC Receptacle And Supplementary Protectors2. 12 3 8 Weld Output Terminals And Selecting Cable 2 5 13 3 9 Connecting Weld Output Cables 13 3 10 Remote 14 Receptacle 14 3 11 Remote 14 Receptacle RC8 Information 14 3 12 Electrical Service 15 3 13 Placing JUMPER LINKS Sn SA Vr UR aw Pelee ak RERO ER Near fll 15 3 14 Connecting Input 16 SECTION 4 OPERATION einen MAR SED see gu ES edo 17 4 1 Controls ues zac npe epp Aad A REIR EOM EPA 17 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 17 5 1 Routine Mainteriance ess 1 ex ye eere ae ERR xe rr REOR E ee die 17 5 2 Fuse Fi cate te ede Ralls Ae bein goa anne RI rud qais 18 5 3 Short Circuit Shutdown 18 5 4 Troubleshooting Table 55e Thren mente RO ep ee penu m 19 SECTION 6 ELECTRICALDIAGRAM 2 Rx kRIleS eR remp 20 SECTION 7 PARTS LIST 22
3. 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 m Or Less 45m 60m 70m 90m 105m 120m Turn off power before connecting to weld out put terminals Welding 10 60 60 100 Do not use worn dam Amperes Cycle Duty Cycle 10 100 Cycle aged undersized or poorly spliced cables 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 Negative 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 22 0 230 240 330 3 30 All Other 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 Materials 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 4 volts or less drop or current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes 3 9 Connecting Weld Output Cables S 0007 E Per Tools Needed 3 e 3 4 in 19 mm 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 Correct Installation Weld Output Terminal Do not place anything between weld cable terminal
4. 2241 209 815 2006 03 Miller Gas Metal Arc MIG Welding re Flux Cored FCAW Welding FC EM Air Carbon Arc Cutting i al anc Gouging Description 1 EJ Arc Welding Power Source Delta Fab OWNER S MANUAL File MIG GMAW I b Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 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 y
5. noc ohne eine nec REFERRI ESQ SRIESSIBECOER 22 OPTIONS AND ACCESSORIES WARRANTY Notes SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 4 Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks a special safety message EF Means Note not safety related 1 2 Arc Welding Hazards A A A pum The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power i
6. e e e 43 ay c10 enu c12 a SCR SCR SCR 4 T 5 T 6 2 2 e GROUND CURRENT NEGATIVE SENSE OPTION c5 9 B JAMES 2725 9 T aM RCI3 AANA AANA AAA REED 2 PLIGI ONN mr NT o TURNS FED LIT trae amp 1 Sogn pper iz 69 occ o zv xg amp amp 260 AK SZ RC4 6 1 i CONTROL BOARD re e Rc4 2 RCI PLG1 RC2 PLG2 3 E RC3 PLG3 RD4 PLGA lt Ro4 4 43 oon e sig I o4 LS Go de qox N N 5 E gg g 8 g 9 2 o 2 aay 2 VV VV 43 i 45 42 2 57 29 or 4 77 43 76 47 48 73 lt PL 2 P BuU 4 7 7 rh W 82 LE 4 2 o w Kez ET aiat z 5 TN H i se mI BR CR SIL 2 ve al 4 3 x z xl gt OFF gt 2 3 7 De RM s 8 e 2 QN g z g 2 8 B y 15 amp 8 4 dox D 2 23 Lore J if god B 1 go 2 3 A 2 CR 8 o 8 8 8 rol _ gt vv 48 a T een 9 T W 7 I Belg 12 SENSOR OPTION _ CR Rcs B F Hood UeeeM M 5 8 Remote J 9 ng Peres POWER Rea ACA ON OFF K GA amp WARNING Do nat touch live electrical p
7. And L3 W to disconnect device line terminals 11 Over Current Protection Select type and size of over current protection using Section 3 12 fused dis connect 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 2241 Page 16 4 1 SECTION 4 OPERATION Controls 29 4 LAM 4 5 E D Miller Delta Fab CV Welding Power Source 1 Voltage Meter 2 Amperage Meter Voltmeter and ammeter display actual output voltage and amperage 3 Power Switch With Indicator Light 4 High Temperature Shutdown Light 209 383 Weld output studs are energized by controls on the wirefeeder Turn Off power before connecting re mote device SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance EP Disconnect input power before maintaining Replace labels Blow out or monthly 3 Months unreadable 6 Months vacuum inside During heavy service clean Z AV NI ER t cable Clean and tighten weld terminals Repair or replace p cdi Au cracked FLZ weld o T OM 2241 Page 17 5 2 Fuse F1 gt Disconnect input power be fore opening rear access door 1 Fuse Holder Cove
8. United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
9. 0 Disconnect and lockout tag 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 Links Move jumper links to match input voltage Close and secure access door or go on to Section 3 14 230 VOLTS 460 VOLTS 575 VOLTS 1 AAAA FRA ARAA o o ARAR A Ref S 174 973 Tools Needed 3 8 p 3 8in Ys Do not overtighten jumper link nuts Ref 800 103 A OM 2241 Page 15 3 14 Connecting Input Power Per 3 N Tools Needed 3 3 8 CO 38in SS GND PE Earth Ground Me T mone GND PE Earth Ground A Installation must meet all National and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in put power before connecting input conductors from unit A Make input power connections to the welding power source first Always connect green or green yellow conductor to supply groundi
10. Item 33 continued MT PLG2 185626 CONNECTOR body 56 1 PE2 1595222 LED yellow copie ete Dp e ex e dn eld eor RETE x 1 siga ri S 159036 LENS LED clear 1 14345 BO VA sau n 118 901 METER Amp lt T Xr aree E ea terio e danse 1 iex d sea rada 118 902 METER Voll ess err RR tea ded aci ac Ea dos Cd ga 1 SN iH 010381 CONNECTOR rectifier 3 Lil EL 228 672 LABEL weld cable lug 3 PSE 227 980 LABEL caution output terminal connection 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Hardware is common and not available unless listed Figure 7 3 Rectifier Si Diode SR1 803 396 A Item Dia Part No Mkgs No Description Quantity SR1 175 070 Figure 7 3 Rectifier Si Diode Fig 7 1 Item 34 1 C7 12 048420 CAPACITOR cer disc 01uf 1000VDC 6 NAP RE MG 177 316 HEAT SINK 3
11. RS E E EE EE 177 317 HEAT SINK TOC i oci teet en ate so ed eni 2 166 667 CLAMP thyristor 3 ursus TP3 185679 THERMOSTAT NC 1 6 SCR1 6 148091 THYRISTOR SCR 865A 300V hockey 6 MD MO DE PLG1 158720 CONNECTOR amp SOCKETS 1 rap 188 692 CLAMP thyristor rectifier 4 250 3 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 2241 Page 25 Hardware is common and not available unless listed 800 707 B Figure 7 4 Panel Rear w Components Item Dia Part No Mkgs No Description Quantity Figure 7 4 Panel Rear w Components Fig 7 1 Item 19 aec 173283 CHAMBER plenum 14 in 1 pm 180 165 BLADE fan 14 in 3wg 28deg 375 bore COW 1 Ml gs xus regum 162 807 PANEL Tear sic cores Re erp Lu pe ne Ya Sa 1 E 168 343 HINGE door primary 2 eri eode eie ees 162 818 DOOR access primary 1 sige Os TE es 217 733 LABEL warning electric shock amp input power EN F
12. and NFPA 51B for hot work and have a fire watcher and extinguisher nearby EIC FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2241 Page 2 a BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed e e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high CYLINDERS can explode if damaged 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 Ins
13. fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as
14. fil la pointe de contact Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 2241 Page 6 distance Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma elle peut exp
15. la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique la terre de mani re incorrecte ou impropre constitue un danger pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous 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 pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le cou
16. ouo 217 136 LABEL warning electric 2 220 2 eu 163 583 BASE ooi chase ea yr AERA deat a ee ae aaa ets 1 24 1 221925 CAPACITOR ASSEMBLY includes 1 tie 163 535 CAPACITOR elctlt 160000 60VDC 6 26 usse IR 182660 BUS BAR mtg capacitor 2 siis R6 140002 RESISTOR WW fxd 10W 500 ohm 1 ED Vie a eA 162817 BUS BAR 2 429 so T1 218407 TRANSFORMER pwr main 230 460 575 1 TP1 2 175405 THERMOSTAT NC Included w T1 2 TE PLG13 218413 HOUSING plug pin skt service kit 1 t RC13 218408 HOUSING plug pin skt service kit 1 Mp 161 294 BRACKET mtg 2 SERERE Fig 7 2 PANEL front 1 94 SR1 210172 RECTIFIER si diode Fig 7 3 1 Part of Option 195 048 Ground Current Sensor When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Par
17. 0 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 INSTALLATION 3 1 Specifications Amperes Input at Rated Load Output 60 Hz Three Phase Voltage Range Rated Welding Output DC Max OCV DC 230V 460 V 575 KVA 375 35 Volts DC 10 45 45 69 34 5 27 5 27 5 17 5 100 4 2 1 6 1 61 0 46 While idling 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output s
18. ACITOR cer disc 05 UF 500 VDC strip 4 apo ERE 204443 PANEL front 4 enia REDIERE Rb aV e RE V Y xax doe He 1 8 POS 181 245 TERMINAL pwr output red 2 9 2 4 5 128750 CAPACITOR cer disc 1uf 500VDC 3 161 303 SPRING 600 OD 072 wire 1 500 19 3 11 NEG 181246 TERMINAL pwr output 1 18 eiie 209 573 PLATE control lower 1 19 Ives 217 865 LABEL warning electric shock and reduced air 1 14 Eds 172 587 COVER stud output 1 160 935 4 CEIP spring e etuer taret bees they e qe a id x Seine 601 835 NUT 10 32 DIS ie Lbs debe e certas t atero 038 887 STUD pri bd brs 10 32 x 1 375 views 209 382 PANEL front upper NAMEPLATE order by model and serial number 1 20 S2 159039 SWITCH rocker SPDT 15 125VAC 1 OM 2241 Page 24 Item Dia Part No Mkgs No Description Quantity Figure 7 2 Panel Front w Components Fig 7 1
19. D K Chassis common G Circuit common for 24 and 115 volts ac circuits REMOTE POWER ON OFF To remote On Off switch Voltage sensing signal from Negative weld output terminal REMOTE VOLTAGE SENSING Am Voltage sensing signal from Positive weld output terminal Not Used OM 2241 Page 14 3 12 Electrical Service Guide Input Voltage 230 460 575 Input Amperes At Rated Output 69 34 5 27 5 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 80 40 30 Normal Operating 3 100 50 40 Min Input Conductor Size In AWG 4 4 8 10 Max Recommended Input Conductor Length In Feet Meters 92 128 135 Min Grounding Conductor Size In AWG 4 8 10 10 Reference 2005 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class 5 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 3 13 Placing Jumper Links Per
20. NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Boo m Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre 3 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s Symbole graphique d avertissement Atten
21. R 1 c e 602 177 SCREW set 250 20 x 250knript sch stl 2 dei de ME M 124 274 BRACKET mtg fan motor 1 R3 097 459 RESISTOR WW fxd 375W 20 ohm 1 se dO dus FM 208 402 MOTOR 1 12HP 230V 1550RPM 50 60Hz 83A 1 ST e eeu 010467 CONNECTOR clamp cable 1 250 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2241 Page 26 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 Miller Effective January 1 2006 Equipment with a serial number preface of LG or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warrantie
22. air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 2241 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burn
23. and copper b Supplied Weld Output Terminal Nut 1 2 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output ter 4 803 778 Incorrect Installation minal Slide weld cable terminal onto weld 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 2241 Page 13 3 10 Remote 14 Receptacle RC8 Per Turn off power before necting to receptacle 1 Remote 14 Receptacle RC8 Connect feeder to RC8 Ref 800 166 D 3 11 Remote 14 Receptacle RC8 Information Socket Information OUTPUT A 24 volts ac Protected by supplementary protector CB2 24 VOLTS AC CONTACTOR B Contact closure to A completes 24 volts ac contactor control circuit C Command reference 0 to 10 volts dc REMOTE OUTPUT CONTROL D Remote control circuit common E 0 to 10 volts dc input command signal from remote control F Current feedback 1 volt per 100 amperes A V AMPERAGE i VOLTAGE H Voltage feedback 1 volt per 10 arc volts Vo OUTPUT 115 volts 15 amperes 60 Hz ac Protected by supplementary protector CB1 c CONTACTOR J Contact closure to completes 115 volts ac contactor control circuit GN
24. arts Disconnect input power or stop engine before servicing ircuit Diagram Figure 6 1 C OM 2241 Page 20 Do not operate with covers removed Have only qualified persons install use or service this unit SHOCK HAZARD Notes OM 2241 Page 21 SECTION 7 PARTS LIST Hardware is common and not N available unless listed q NY KOT 0 QU 23 803 388 B Figure 7 1 Main Assembly OM 2241 Page 22 Item Dia Par No Mkgs No Description Quantity Figure 7 1 Main Assembly a d suce 179430 PANEL side eoe pde px X RN 2 ETE 179429 COVER TOP eaten ERE MI RR QUI pte epe 1 LO ss reU 209 104 BAFFLE aif ood UE epi rep 2 WE dices dr tre 162816 CHANNEL 4 2D QVE kate 162820 BAR mtg lift 2 177 279 GASKET MEVE eta 1 LU vx reu ed 162830 4 LIET EYE feral iad ee Prem Nus Iu re 1 DO suus 604 536 SCREW 312 18 x 1 75 hexhd pln gr 5 2 e usc Z1 209 807 STABILIZER one Le doh A ee
25. e 1 10 HD1 168829 TRANSDUCER current 1000A 1 TEE PLG14 115094 CONNECTOR amp SOCKETS 1 OH eat da wei 173 605 BRACKET mtg contactor 1 12 C21 28 163 906 CAPACITOR 50 and 60 2 3 dents T2 159 042 TRANSFORMER control 50VA 24V 230 460 575 60Hz 1 14 TE1 159244 PRIMARY BOX consisting of 1 iut 601 835 NUT 10 32 DIS 2 at Eee EI dare ee Rc alae 24 AG edens 038 887 STUD pri bd brs 10 32 x 1 875 24 doro co M ees 010913 WASHER flat 218 ID brs 24 601 835 NUT 10 82 DIS ce ieee CF Sed 038 618 LINK jumper term bd pri 8 Tif mmt sin 159 034 HOLDER fuse mintr 1 2 182 F1 156 065 FUSE 5A 600V time delay 1 Fig 7 4 PANEL rear w components 1 23520522505 W 160 793 CONTACTOR def prp 60 24VAC 1 eels CR4 140750 1 SWITCH reed uei recie reum bu XR ul AL 1 x22
26. ed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 2241 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York
27. equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill APA This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are 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 accordin
28. er des cartes ou des pi ces Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes PC gt amp DES ORGANES MOBILES peuvent provoquer des blessures e pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geant le fil de soudage PAL DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels AJ que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettreles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des in
29. erre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions vanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxi ques en cas de soudage OM 2241 Page 5 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous vo
30. et out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2006 Miller Electric Mfg Co 2006 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters
31. g to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for 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
32. ity 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 nn LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle ee e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards gt e Puton grounded wrist strap BEFORE handling ASS boards or parts eo e Use proper static proof bags and boxes to store move or ship PC boards amp MOVING PARTS can cause injury e Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 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 P MOVING PARTS can cause injury Keep away from moving parts such as
33. liant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil SUR ar nn L EMPLOI EXCESSIF peut CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste nn an amp LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipul
34. loser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d p
35. ng terminal first and never toa line terminal See rating label on unit and check input voltage available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 3 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 conductor to welding power source grounding terminal first If unit is equipped With optional ground current sensor route grounding conductor through reed switch two times and connect to grounding termi nal 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 terminals Close and secure access door on welding power source Disconnect Device Input Power Con nections 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
36. on rear access door 6 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 800 453 A 3 5 Tipping careful when placing or moving unit over uneven surfaces OM 2241 Page 11 3 6 Dimensions Weights Dimensions A 30 in 762 mm including lift eye B 23 in 585 mm 30 1 2 in 775 mm including strain relief D 27 1 2 in 699 mm E 3 4 in 19 mm 4 Holes F 21 1 8 in 537 mm G 1 1 8 in 29 mm D H 7 16 in 11 mm Dia Weight L E 381 Ib 173 kg 801 530 3 7 115 VAC Receptacle And Supplementary Protectors Turn Off power before con necting to receptacle 1 115V 15A AC Receptacle RC9 Power is shared between RC9 and Remote 14 receptacle RC8 see Section 3 10 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects the 115 volts por tion of RC8 and RC9 from overload CB2 protects the 24 volts ac portion of RC8 from overload Press button to reset protector Ref ST 800 166 D OM 2241 Page 12 3 8 Weld oo Terminals And Selecting Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding
37. onents such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by 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 Mille
38. ou can count on years 90 00012000 of reliable service with proper 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 CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage stor qe ER ERA n e POUR eae ea 1 1 2 Arc Welding Hazards ups e d puce c ISSUE USE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 08 3 1 5 Principal Safety Standards
39. que rester danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusementavec des protections homologu es Ne pas souder dans un endroit des tincelles peuvent tomber sur des substances inflammables Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le
40. r 2 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 Close and secure access door 1 Tools Needed C H 3 8 S Turn Pull Out And Replace Fuse Turn Install Flat End Of Fuse Into Cover Ref 800 101 C 5 3 Short Circuit Shutdown When contact tip is shorted and sticks to workpiece the unit output falls to a safe operating level To resume operation release gun trigger turn Off unit and remove contact tip from workpiece Check contact tip and replace if damaged Turn On unit to continue operation OM 2241 Page 18 5 4 Troubleshooting Table Trouble Remedy No weld output unit completely inoperative Place line disconnect switch in On position see Section 3 14 Check fuse F1 and replace if necessary see Section 5 2 Check and replace line fuse s if necessary or reset circuit breaker see Section 3 14 Check for proper input power connections see Section 3 14 Check for proper jumper link position see Section 3 14 No weld output Power switch pilot light on fan on Check repair or replace feeder see wire feeder Owner s Manual Unit overheated Allow unit to cool with fan On see Section 3 2 Have Factory Authorized Service Agent check control board PC1 Unit provides only maximum or mini mum weld ou
41. r authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be 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 s
42. rant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour la sant e D autres consignes de s curit sont n cessaires dans les conditions Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de Sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants e
43. recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 2241 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 Toronto 416 747 4044 site Internet www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 191
44. s Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off 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 e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 2
45. s d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l Etat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manip
46. s expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders In
47. s on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 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
48. se la terre le faire directement avec un Seulun personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil Ne pas toucher l lectrode quand est en contact avec la pi ce la terre Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine H n n x sonnes notamment les enfants de l appareil Ne pas toucher des porte lectrodes connect s deux machines m me temps cause de la pr sence d une tension vide doubl e UNE DECHARGE ELECTRIQUE peut e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le 9 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures un r r js t 5 ji mi nt graves Le circuit de l lectrode et de la pi ce est dese el que ous GS PANNEAUX El couvercies sont correcementen sous tension lorsque le courant est d livr la place p sortie Le circuit d alimentation et les circuits internes de la machine Fixer le cable de retour de fa on obtenir un bon contact metal metal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou
49. short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 2241 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Box 9101 1 Battery March Park Quincy 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compress
50. t les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxyg ne provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger _ e Installer le poste correctement et le mettre la terre convenablement pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de puiv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute 2x ment toxiques et irritants Toujours v rifier la terre du cordon d alimentation V rifier et s assurer Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne de t
51. tall cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 4 Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capac
52. terf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e Lutilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En ca
53. tion Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints Indique un message de s curit particulier Ce groupe de symboles signifie Avertissement Attention Risques d p d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce manuel V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions en L quipement doit tre hors tension lorsqu il n est pas utilis matiere de securite indiqu es ci dessous ne constituent qu un Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus completes fournies ou mal piss s gans les normes oe dans la Section 2 5 Lireet 6 pas enrouler les c bles autour du corps e USA Pa 3 Sila pi ce soud e doit tre mi
54. tops and cooling fan runs Wait fifteen minutes for 8 500 unit to cool Reduce amperage 400 duty cycle before welding 1 Exceeding duty cycle can 300 damage unit void warranty Lu e 200 100 10 20 40 50 60 70 80 90 100 96 DUTY CYCLE 100 Duty Cycle Continuous Welding Overheating Co 0 V peu OR Minutes Reduce Duty Cycle Soo eit OM 2241 Page 9 3 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 60 50 MAX 40 30 DC Volts 20 MIN 100 200 300 400 DC Amperes 500 600 700 800 209 811 OM 2241 Page 10 3 4 Selecting A Location PR Movement 1 8 lt P od Location And Airflow INPUT SERIAL NO 18 460 mm 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Non CE Models Only Use rating label to determine input power needs Label located under front access door 4 Plate Label CE Models Only Label located under front access door 5 Rating Label CE Models Only Use rating label to determine input power needs Label located
55. tput Have Factory Authorized Service Agent check control board PC1 Erratic or improper weld output Use proper size and type of weld cable see Section 3 8 Clean and tighten all weld connections Check wire feeder installation according to Owner s Manual Have Factory Authorized Service Agent check control board PC1 and or SCR in main rectifier No 115 volts ac output at duplex receptacle or Remote 14 receptacle Reset supplementary protector CB1 see Section 3 7 No 24 volts ac output at Remote 14 re ceptacle Reset supplementary protector CB2 see Section 3 7 Fan not operating Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor OM 2241 Page 19 218 521 SECTION 6 ELECTRICAL DIAGRAM n HD1 25 LEE 1 T t A 1 1 g tr POSITIVE STAINLESS ESAE m STEEL 07 x 8 NzYsYaY ALUMINUM SR SOR SgR bo a un TO positive 7 ALL OTHER m MATERIAL 23 581 2 8 I 24 4
56. tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels DES PIECES CHAUDES peuvent provoquer des br lures graves Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardia
57. ts 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 2241 Page 23 Hardware is common and not available unless listed 2 803 389 C Figure 7 2 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 7 2 Panel Front w Components Fig 7 1 Item 33 og ETE 159863 ELECTRONICS BOX dte he ae eds 1 2 1 209627 CIRCUIT CARD control 6 2 1 PLG1 158720 CONNECTOR amp SOCKETS hee PLGS 115 094 CONNECTOR amp SOCKETS 1 ipa anis PLG4 162382 CONNECTOR amp SOCKETS 1 PLG2 115091 CONNECTOR amp SOCKETS 1 3 CR5 006 393 RELAY 24VAC 1 4 1 2 093995 SUPPLEMENTARY PROTECTOR man reset 15 250VAC 2 9 604 176 RECEPTACLE str dx 2 15 125 1 eee eee 210 281 CONNECTOR CAPACITOR w leads includes 1 RC8 143976 RCPT w service 11 C3 6 13 14 097749 CAP
58. ulation OM 2241 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association Box 9101 1 Battery March Park Quincy 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de
59. verter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor 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 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 comp
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