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Miller Electric D-64 User's Manual

1. a el PLGB3 PLG106 FSI PLG106 Ps LK RED RED WHT VOLTAGE SENSE COOLANT FLOW lt lt gt 2 gt RIGHT SWITCH OPTIONAL N3 HEAD GPTONAL es House L J of r LEFT Ro1 7 SZ tes sa p gt RC1 5 gt gt gt 5 gt s RC1 2 gt gt gt 2 gt 2 gt 2 REID Hg 3 gt RC1 4 gt gt gt 4 iyt RC1 8 gt 8 gs Re1 1 gt gt gt gt 12 l Z RC1 6 gt gt gt 6 gt 6 gt PLG1 PLG1 b GS1 3 GS2 H ba PLG11_ A A A Ap RC2 4 KAPOY RC53 4 PC2 E ATA FR 4 5 RC2 5 DK RC53 5 JUMPER BOARD PLG3MA N A 1 g2 FOURS Rc27 Y N a g IN Jo Rc2 2 gt lt RC53 2 Rose pieo AMA lA ES RC2 6 gt RC53 6 PLG27A A A zl lz A A AP A Re2 1 gt gt Eo Rc53 1 5l IE 10 PLG28 PLG38 Rc2 3 gt gt Ress 3 4 5 gl lz8 4 PLG34 PLG27 RC30 PLG12 Roy Y V l I Y Y Y RC40 9 3 N la N lo BK de lt gt lt l ga ross iko Lrusaa AY PS EA Kris CR101 RCS3 PLESS 4 5 8 4 5 b RC54 PLG54 PL62h APLGIB RC58 PL656 RC54 1 gt gt pr r 7 TAOHOMETER YO Y N 6 X N o K1 ZEN Res R0543 gt gt PLG11 PLG2S PLG29 uD RT AT AK RR RR R A A KA pa A o Q Tis 1 1 1 gt dr a gt PLG33 PL637 RC40 P g g gme GE nove 3 8 88 888388 8 3 8 aK 7 7 PLO18 BB ON Zeros E
2. WITH REMOTE DIGITAL CONTROL OPTION CONNECT AS FOLLOWS RC63 PLG60 TRIGGER OFF CONT TRIGGER ON PCO RC41 PLG41 Koto HOLD BURNBACK caz ploes RO43 PLG43 8 SAN Fp SPOT a SO OPTIONAL lt lt RC7B 3 RC44 NO_ CONNECTION i AIR REZ AER RC11 PLG31 as RO76 6 gt RC45 PLG61 RC78 4 1 lt 8 Plo32 lt RC31 8 1 y lt Rc3i 8 Y y lt RC11 8 api RC76 5 gt WHEN DIGITAL VOLTAG CONTROL IS USED WITH 77 ge 8 B oB aa 8 8 lt RO7B 2 AN INVERTER POWER SOURCE MAKE THE aT 71 Reg B g S lt res 7 9 9 lt RO11 7 ay E RO76 4 FOLLOWING CONNECTIONS TO PC40 ad lt s sel lt R 3 6 pezo RIGHT lt RES1 6 lt RC11 6 _ id EN RC41 PLG61 pa GPRONAL s f RC42 NO CONNECTION lt 2 2 lt 4 lt Rcsi 2 lt RC31 2 Rem lt RC11 2 5 RC100 PLG100 PLG80 RC76 3 gt RC43 PLG43 PREFLOW PC31 87 RC44 PLG42 K3 OPTIONAL tale lt 4 lt RO79 4 lt 5 5 lt lt RC31 5 POSTFLOW lt RC31 5 lt RC11 5 pa pa JAN RC76 1 gt gt RC45 PLG41 2 SPOTTIME i TRIGGER HOLD lt 5 lt lt s lt lt RC79 5 Ta BURNBACK lt 3 lt Rc31 3 BURNBACK y lt Re31 3 lt RCI1 3 RIGHT 7 I RC31 PL631 fi ole lt 2 lt RC79 2 r lt 4 lt RC31 4 lt RC31 4 RCSS PLGSS lt RC11 4 DIGITAL
3. ae PLG19 151 490 CONNECTOR rect 21P ee eee PLG60 63 138 045 CONNECTOR 8 SOCKETS 2 AA AA ae Le 097022 KNOB aa AN a MAN ANA een ee ta muk nu nee T see Figure 8 3 amp Figure 8 5 for additional parts 4 PC60 157 719 CIRCUIT CARD meter dual 1 ee PC51 198 004 CIRCUIT CARD digital tach EEUE EE N 139 231 CASE SECTION bottom rear 1 7 BEA senate PET Hess 198 037 CIRCUIT CARD motor control 1 EER sara PLG1 115092 CONNECTOR amp SOCKETS EE aa PLG2 115093 CONNECTOR 8 SOCKETS ER as PLG3 115094 CONNECTOR amp SOCKETS eee Le PLG4 115091 CONNECTOR amp SOCKETS ee PLG5 130 203 CONNECTOR amp SOCKETS ree dote PLG6 136 810 CONNECTOR amp SOCKETS RE sere kasa Ee 151 187 LATCH slide flush 1 MOSS CB1 083 432 CIRCUIT BREAKER man reset 1P 10A 250V 1 EO Susan 111 997 SWITCH rocker SPST 10A
4. scene PLG98 131 056 CONNECTOR 8 SOCKETS 1 O eb sas EES 115443 STAND OFF 6 32 x 750 lg 4 RE EE esa 138 542 SPOT BURNBACK PREFLOW POSTFLOW RH 1 MR EA EE eee138 547 SPOT BURNBACK PREFLOW POSTFLOW LH consisting of 1 Qs AL Sue EE 126 689 STAND OFF 6 32 x 1 500 g 2 fat Ds PC30 188 834 CIRCUIT CARD 4 in 1 timer 1 Sey usata PLG1 21 31 115 092 CONNECTOR 8 SOCKETS 8 Ji Bee PLG22 32 135409 CONNECTOR 8 PINS 2 BE ae Ee PLG35 115094 CONNECTOR 8 SOCKETS 1 RE ya Ee PLG90 131 204 CONNECTOR 8 SOCKETS 1 DER aysa la PLG91 115093 CONNECTOR 8 SOCKETS 1 i BI iis ten pau tarde 093 551 KNOB PoiNIEF sean naines fun bene sea di an BARAN KAG 4 eed ER MA EE t 180 636 PLATE control 1 N OF OS OE 133 344 PANEL option 1 oa ELE OE NG 120 304 BLANK snap in nyl 250mtg hole 2 Re sl 060194679 RUN IN CONTROL consisting of KAG EE EA ED ER EE EE LO ES 158037 SWITCH reed anne sma EE e
5. ENS PLG96 131 204 CONNECTOR 8 SOCKETS 1 va PLG98 115 094 CONNECTOR 8 SOCKETS 1 R PLG11 17 115 092 CONNECTOR 8 SOCKETS 2 ELE PLG12 18 135409 CONNECTOR amp PINS 2 A EE ET 120 304 BLANK snap in nyl 250mtg hole 4 OM 1582 Page 27 Description Quantity Figure 8 2 Control Box Fig 8 1 Item 26 Continued sare aap uka aa EE 119 951 BLANK snap in nyl 437mtg hole 6 EE tate ersten 107 983 BLANK snap in nyl 500mtg hole 2 ne ST AE 024 103 BLANK snap in nyl 750mtg hole A CE 000 527 BLANK snap in nyl 875mtg hole A 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 2 Hardware is common and not available unless listed lt See Option that is applicable OM 1582 Page 28 Z x of Ne lt A D RL See Figure 8 2 Nz e N 143 227 D Figure
6. lei SA O as Sates ais 604772 WASHER flat sI SAE No 8 1 1 PP zu puak o i us us 182156 SPRING GPISI 2 RE Ge Rg uya det cadet Shel yau ANA AA 2 4 a a mena manae 182155 SPRING uuu cots PI MANONG beac nc uit awa sarap EER ee ects Bee RE lise TETN OE AA NEA KI AGA 132746 BUSHING spring 125202 Swa OO su cold te EN 181 522 ss SHART SPNO y nG as Gee p ee vie NG Ee be a Ted og wa pakaq maa A Tess d ME DE DT EA 132 747 CARRIER shaft Disco MEE ihe O Anda 133 739 WASHER flat buna 375 ID x 625 OD x 062thk 1 1 ME ETE 183 330 KNOB w extension Ts sed 24 PC51 ee198 004 CIRCUIT CARD digital tach consisting of Ms rates PLG57 131 204 CONNECTOR 8 SOCKETS 1 1 ES Pasia 604 311 GROMMET rbr 250 ID x 375mtg hole 062 groove 1 1 EEN PLG58 131 203 CONNECTOR 8 PINS 1 1 SEED As AR Ee 132611 OPTICAL ENCODER DISC Tasse wt BO ayq u Q bsa PA La 167 387 e SPACER lo atind u bee NENA bake BANGA KANG DANG KNA at s Dna e O yuca 168 825 DRIVE pinion Tia d ROOM ER ee ass 133 308 RING retaining ext 375 shaft x 025thk
7. Tes A A EE N 134 834 HOSE SAE 187 ID x 410 OD order by ft aft 2ft Jacana RES PANGA GEES N 149 959 FITTING brs barbed M 3 16tbg x 312 24 1 1 RCE acs achu patuta a 179265 ADAPTER gun feeder LH 1 1 AE tec ove wicks edit 179 264 ADAPTER gun feeder RH 1 1 Pee Be Ki Put Qha a 108 940 SCREW cap stl hexhd 250 20 x 750 4 4 A es cess eee SG 604 538 WASHER flat stl SAE 312 Vetere A Bf OME EER se 151 437 KNOB piste T 1 125 lg x 312 18 x 1 500 eae E 151 290 SCREW mach stl hexwhd 10 32 x 500 Dita tes 2 Me SA TE HI 179 277 COVER drive roll consisting of anag AE AI 178937 LABEL warning electric shock 1 1 n AT ne EE PANDA 601 872 NUT stl hex full fnsh 375 16 AO PAR PARE esas 602213 WASHER lock stl split 375 1 1 EE te sby Casu 602 243 WASHER flat stl std 375 he AO nts heed net nie 601 966 SCREW cap stl hexhd 375 16 x 1 250 Luson Optional High Speed Motor Recommended Spare Parts Part of Optional Tach To maintain the factory original performance of your equipment u
8. 6 TE EON A 180 635 PLATE control 2 Part of Optional 138 542 RH and 138 547 LH Spot Burnback Preflow Postflow Part of Optional 172 825 RH and 173 748 LH Digital Dual Schedule OPTIONAL 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 gt Hardware is common and not available unless listed See Table 8 1 For 14 Drive Roll amp Wire Guide Kits Ng 137 222 P Figure 8 5 Drive Assembly Wire OM 1582 Page 31 Item Dia Part No Mkgs No Description Quantity 2 4 Figure 8 5 Drive Assembly Wire Fig 8 1 Items 15 amp 25 ai HANG od a ad 010668 SCREW cap stl sch 250 20 x 1 500 2 4 EE RE DAN 172 075 CARRIER drive roll w components 2 4 Siig O Yaun EN 149 962 SPACER carrier drive roll 2 4 a AMG Qi suny N 149 486 PIN rotation arm rocker Phare A re 132750 ARM pressure ls ds Ons KA EA NGA 150520 SPACER flat stl 257 ID x 619 OD x 105 1 2 A MAGNG tien lt 133493 RING retaining ext 250 shaft x 025thk 2 2 O hee eee DE sert 196 950 s PIN hinge iia rene tate a tn
9. 2 EE Baa et Fig 8 5 WIRE DRIVE ASSEMBLY LH 1 ER E Fig 8 2 CONTROL BOX 1 EE 108 008 REEL wire 60 lb consisting of 1 oF Oe at antecedents 124 900 SUPPORT reel Spool 1 A rete Meee teeta 168 104 RETAINER spool support consisting of 1 Na PE usq 166 594 LABEL caution falling wire reel can cause damage 1 wn SOL Lure diets 168 103 NUT spanner retaining 1 AE RA TE 143 838 CABLE weld 26 in EE us ou ces 164 059 HOSE gaS 542 ida data a aswaa I 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 1582 Page 25 Hardware is common and not available unless listed 143 226 G Figure 8 2 Control Box OM 1582 Page 26 Item Dia Part No Mkgs No Description Quantity Figure 8 2 Control Box Fig 8 1 Item 26 TEER thes states 139 235 PANEL side lower LH
10. Insulation Coordination For Equipment With Low Voltage Systems Part Principles Requirements and Tests IEC 664 1 October 1992 First Edition Electromagnetic Compatibility EMC EN 50199 August 1995 European Contact Mr Danilo Fedolfi Managing Director MILLER Europe S r l Via Privata Iseo 20098 San Giuliano Milanese Italy Telephone 39 02 98290 1 Fax 39 02 9828 1 552 dec_con 11 96 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ih A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols gt Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away ER 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 Th
11. 66 OS 815 6v E66 091 E E N amp 911191 40119813 9ZIS M aping ajeipawiau UI 220 890 UI GZ0 EZ0 OM 1582 Page 33 Notes OM 1582 Page 34 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 The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA 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 t
12. Check interconnecting cord connections If secure check cord for continuity and repair or replace see Sections 4 3 and 4 4 Wire feeder is on meter s do not light up motor does not run gas valve and welding power source contactor do not pull in Check and reset CB1 see Section 5 2 Electrode wire feeding stops or feeds er ratically during welding Check gun trigger connection See gun Owner s Manual Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 4 9 Change to correct size drive roll see Table 8 1 Clean or replace dirty or worn drive roll Incorrect size or worn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around nozzle opening Have Factory Authorized Service Agency check drive motor or motor control board PC1 Motor runs slowly Check for correct input voltage Wire does not feed until trigger is pulled but continues to feed after trigger is re leased and trigger hold is not on Check for a short between welding gun trigger leads and weld cable Repair short or replace welding gun Gas valve in feeder is rattling loudly along with possible erratic or slow wire feed speed Check for a short between welding gun trigger leads and weld cable Repair short or replace welding gun Unit does not switch out of Run In Speed When
13. q DES ORGANES MOBILES peuvent provoquer des blessures Ng e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication 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 appa reil 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 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 risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipem
14. 1 Rd VA EE IN Fig 8 4 CONTROL PANEL 2 e PC2 134 994 CIRCUIT CARD tach jumper 1 Atak SR AE 180 314 DIGITAL DISPLAY consisting of 1 ER eee a kas ne 132 611 OPTICAL ENCODER DISC N PC50 132 370 CIRCUIT CARD tachometer 1 MEER NA e exit 097 132 STAND OFF 6 32 x 375 l9 4 Serre R3 4 603 856 POTENTIOMETER WW sltd sft 10 T 2W 10K ohm Wire Feed Speed A 2 wa aaa N PLG5 130 203 CONNECTOR amp SOCKETS Ma s PLG62 131 055 CONNECTOR 8 SOCKETS Me ays PLG64 167 361 CONNECTOR 8 SOCKETS Na ma PLG95 115 092 CONNECTOR 8 SOCKETS EE 138 045 CONNECTOR amp SOCKETS EE ie R75 85 603 856 POTENTIOMETER WW sltd sft 10 T 2W 10K ohm Voltage Control A 2 EER PLG84 86 97 131 204 CONNECTOR amp SOCKETS 8 gele PLG41 47 49 85 131 203 CONNECTOR 8 SOCKETS 4 tia PLG41 115 090 CONNECTOR 8 SOCKETS
15. Optional See Section 4 10 2 Wire Speed Meter Optional Factory set to display inches per minute If display of meters per minute is desired see Section 4 10 3 Schedule A Wire Speed Control The scale is calibrated in inches per minute x 100 and meter per minute 4 Schedule A Voltage Control Optional For dual schedule applications a dual schedule switch is required for the gun Obtain a proper dual schedule switch and install according to its instructions 5 Schedule B Indicator Light Optional 6 Schedule B Wire Speed Control Optional 7 Schedule B Voltage Control Optional 8 Press To Set Button Optional ST 152 647 Press and hold button to preset Schedule B wire feed speed and or voltage 9 Left And Right Indicator Lights 10 Jog Purge Switch Push up to momentarily feed welding wire at speed set on Wire Speed control without en ergizing welding circuit or shielding gas valve Push down to momentarily energize gas valve to purge air from gun or adjust gas reg ulator Center position is off OM 1582 Page 18 5 2 Overload Protection And Optional Side Panel Controls ef 1 Circuit Breaker CB1 CB1 protects wire feed motor from overload Press to reset 2 Preflow Control Control sets time gas flows before welding wire is energized 3 Spot Time
16. e Ne pas se servir de source lectrique courant lectrique dans les zones Le soudage g n re des fum es et des gaz Leur humides dans les endroits confin s ou l o on risque de tomber inhalation peut tre dangereux pour votre sant e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le e Eloigner votre t te des fum es Ne pas respirer proc d de soudage le demande les fum es e Si l utilisation d une source lectrique acourant lectrique s av re n ces e A l int rieur ventiler la zone et ou utiliser un chappement au niveau saire se servir de la fonction de t l commande si l appareil en est quip de l arc pour l vacuation des fum es et des gaz de soudage e Couper l alimentation ou arr ter le moteur avant de proc der a l instal e Sila ventilation est insuffisante utiliser un respirateur alimenta lation la r paration ou l entretien de l appareil D verrouiller tion d air homologu l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de FA ET Le s curit e Lire les sp cifications de s curit des mat riaux MSDSs et les j A instructions du fabricant concernant les m taux les consomma e Installer et mettre la terre correctement cet appareil conform ment bles les rev tements les nettoyants et les d graisseurs son manuel d utilisation et aux codes nationaux provinciaux et a A E ae municipaux e Travailler dans un espace ferm seulement s
17. 1 ldentifie un message de s curit particulier Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage Varc Les symboles pr sent s ci apr s sont utilis s tout au long du e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le pr sent manuel pour attirer votre attention et identifier les risques champ les pi ces endommag es Entretenir l appareil conform ment de danger Lorsque vous voyez un symbole soyez vigilant et ce manuel suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer e Porter un harnais de s curit quand on travaille en hauteur l information contenue dans les normes de s curit num r es i a la section 1 4 Veuillez lire et respecter toutes ces normes de e Maintenir solidement en place tous les panneaux et capots securite e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal ee L installation l utilisation Ventretien et les r parations ne doi vent tre confi s qu a des personnes qualifi es Au cours de l utilisation tenir toute personne a l cart et plus par ticuli rement les enfants UN CHOC ELECTRIQUE peut t
18. 250VAC Power Switch 1 O o EG 134 201 STAND OFF SUPPORT PC card 312 375 12 TERE AG 010 325 BUSHING strain relief 840 ID x 875mtg hole 1 LE EE era 4139 229 WRAPPER u au apn tee dara ee 1 AS es ren tre 178 936 LABEL warning general precautionary 1 EE TE 134 464 LABEL warning CE 1 TA yalan ES 164368 4 CABLE DWI an naan Sanh ee eek lia 1 A Kh kas 605 227 NUT nylon hex jam 750NPST 2 16 GS1 2 125 785 VALVE 24VAC 2 way custom port 1 8 orf 2 17 GE EER es 147856 CAPACITOR His ERG aa dise nie ene bis phat ke sed ad 1 18 CR101 072 817 RELAY encl 24VAC DPDT 1 19 SR1 035 704 RECTIFIER integ 40A 800V 1 0E VREDE ane 030 170 BUSHING snap in nyl 750 ID x 1 000mtg hole 3 LA EIEN ATENT Fig 8 3 PANEL front w components 1 TE N POS nc cae 183 151 CIRCUIT CARD relay control 1 ise sa oss PLG92 94 131 052 CONNECTOR 8 SOCKETS 2 a se EDE PLG93 115 093 CONNECTOR 8 SOCKETS 1 AA PLG95 135409 CONNECTOR 8 PINS
19. BOARD 54 VV ar OPTIONAL 20 2 6 122 E 87 FA 30 8 SENSOR RC72 PLG72 121 z213 y I H Ro75 P1084 12 rice ie cw RC76 PLG16 VOLTAGE 4 NO RC78 PLG88 CONTROL A RC70 PLG70 Rc7e pLeaa L _ SEE NOTE 2 J PLG41 PLG41 5 s ST 1 gt lt RC75 3 s lt __ qe Se 2 Di 52 52 2 VOLTAGE d A RGIS 2 2 CONTROL 51 2E K Rc75 1 1 lt 2 T Yoeronay 51 ARR AND As ia 54 A ES NA Nb M eces NOTE 3 WHEN USED AS A METER Ya Vs V2 pers OPTION CONNECT AS FOLLOWS RC63 PLG63 WHEN USED AS DIGITAL METERS 197 518 A OM 1582 Page 23 SECTION 8 PARTS LIST gt Hardware is common and not available unless listed 143 225 K Figure 8 1 Main Assembly OM 1582 Page 24 Item Part No No Description Quantity Figure 8 1 Main Assembly wen RE N aes 143 160 HUB 8 SPINDLE ASSEMBLY consisting of 2 PERE ES 058 427 RING retaining spool 1 aa OO ape ee PA ne 180 573 SHAFT support Spool 1 ny ER EE EG 010 233 SPRING cprsn 970 OD x 120 wire x 1 250pld 1 AE te 057 971 WASHER flat stl keyed 1 500dia x 125thk 2 NAG a rus u EES 010 191 WASHER for 656 ID x 1 500 OD x 125thk 2 MEE EER 058 628 WASHER brake stl 2 dT EE EE N 058 428 HU
20. BUTTON switch black 1 EE gan IG AE RE haste 097 922 KNOB pointer 2 see Figure 8 4 For Additional Parts 9 RC8 9 048 282 CONNECTOR W SOCKETS 1 10 ER 134 846 SWITCH tgl SPTT 15A 125VAC Jog Purge 2 e a OE MOE LA 097 922 KNOB pointer 2 AE EE NAM Ra NAMEPLATE order by model and serial number 1 OPTIONAL 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 1582 Page 29 gt Hardware is common and not available unless listed 146 340 B Figure 8 4 Control Panel Item Dia Part No Mkgs No Description Quantity Figure 8 4 Control Panel Fig 8 2 Item 2 pat N asse 881 92 buka 011 770 SWITCH tgl SPDT 6A 125VAC Trigger Hold Spot 2 nal ue eed PC70 150 591 CIRCUIT CARD option interface 1 EE PLG16 54 76 e6115 093 CONNECTOR 8 SOCKETS 8 aus PLG78 88 115094 CONNECTOR 8 SOCKETS 2 ere PLG79 89 115 091 CONNECTOR 8 SOCKETS ates PLG80 90 6135 531 CONNECTOR 8 PINS
21. Control Factory set for 0 to 5 seconds of spot time If 0 to 2 5 seconds is desired see Section 4 10 4 Spot Continuous Switch Switch selects an untimed continuous weld or a timed spot weld 5 Trigger Hold Switch Optional Push up to weld without holding gun trigger throughout the weld cycle To start weld press and release gun trigger within three seconds after an arc has been struck To end weld press and release gun trigger 802 433 A 6 Burnback Control Control adjusts time welding wire is ener gized after wire feed stops 7 Run ln Control Control sets run in wire speed before arc ini tiation 8 Postflow Control Control sets time gas flows after completion of burnback Close side door SECTION 6 MAINTENANCE AND TROUBLESHOOTING 6 1 Routine Maintenance Disconnectpower before maintaining monthly 0 WARNIN Clean and Repair or WA Replace IE tighten replace A unreadable a d cracked S labels terminales weld cable Replace Check Check gas Check cracked 14 pin hose and gun parts cord fittings gt cable 6 Months Blow out or vacuum inside During heavy ie service clean rolls OM 1582 Page 19 6 2 Troubleshooting Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but elec trode wire is not energized
22. E EEREZE lt s lt e LB s gt plea MOTOR y v PE E BOARD Y NY Ro pos o 69 cmo RC1 PLG1 Rode 3 hee HT Th RC2 PLG2 7K RC96 3 RC90 PLG90 Zi El el tie a Res pLes Y V VPI612Y Y Vriusia BAWAT PLGI7 PLG38 ETO O pcayeccs 3 2 7 3 2 KCO3 PLCO3 Y V VPLG29 Y V PLG39 DETACH OPTION ur le R gt le DETACH Ee vel N N Reso A A Rogo OPTION RC96 PLG96 APS APLI EP ya EUA gt N E E lt crces 6 RC99 PLG99 Y Y Yew Y Y Y eed 2 y Y yez gt Y y REST rece lt lt RC6 1 R IS S R lt lt RO94 14 Y y VPLG34 y y PLGSS 1 L a PRE LE r lt lt Rc94 8 Ke RO6 3 Ye Yo Vr Y Y PO Paan me 7 Na a Sig se eR Bros RAL ERAS dad eo 3 2 1 LOG a Oy 88838388883 2392322923 88338 TOR LE SZ VY V V ANA VA ANA VA Y Y Y Y YY ONY lt lt Rees Jy N 8 p VV VV Y Y Y V V V V Y Y a Vas E 22 24 23 57 2720119 OM yYI RC6 2 PC51 eee 3 LEFT RED WET sd RED 64 22 lt lt RC4 9 TACHOMETER TACHOMETER LEDI Reg PICK UP PICK UP 4 3 2 1 By 3 21 PLG19 PLG19 76 BAN 55 RC3 1 gt gt gt PLG25 PLG23 lt A gt d I JEL ne op 18 PLC26 PLG24 lt gt 2 RC3 3 gt gt Pa 4321 4321 Ni LEFT RIGHT Ai mar TRIGGER DETACH OPTION TRIGGER c eM Rc4 2 gt gt F RC4 3 gt gt u 10 ax Die 7 as i pe RC4 4 gt gt sold Xo E s gt WE 8 RC4 5 gt gt ad gbi eg ay RC4 7 gt gt 22 Eu RC4 10 gt gt 2 RIGHT RC5 8 ee s 2 Die Die us us i RC5 4 gt gt 29 Ji s
23. apar 71 EE EA EE 079 878 HOUSING oto ices arene eR OR icin er AR an EER RR s ana e S oe DAE AKNG ue 079 595u a TERMINAL ciao kaa ma pi qam ate a te ae N AKA nee 079 581 00000 CLAMP ities aie ee ts ds l EE EK EER 0483834 is GEAMP oi at a tae eee ie de adan 1 s RES Ee ee re de 180 636 PLATE COMO u ie es Se a We ged ROER eek aya ee Res 1 EE DEE ass 133 344 PANEL option 1 ER SEA 197 153 SPACER mtg pc board 1 OM 1582 Page 30 Item Dia Part No Mkgs No Description Quantity Figure 8 4 Control Panel Fig 8 2 Item 2 Continued 10 PC80 196 746 CIRCUIT CARD run in control 1 rh WU ER AA 093 551 KNOB 125dia shaft w 125 set screw 1 hh thes PLG16 54 76 76 115093 CONNECTOR amp SOCKETS 4 sean ae PLG71 78 88 115 094 CONNECTOR amp SOCKETS 8 suns PLG79 79 89 100 115 091 CONNECTOR 8 SOCKETS 4 PLG80 90 RC100 135 531 CONNECTOR 8 PINS 3 seein nese PLG98 131056 CONNECTOR amp SOCKETS 1 ee ate RC70 048 282 RECEPTACLE amp SOCKETS 1 RT EE A 120 304 BLANK snap in nyl 250mtg hole
24. as shown by the symbols B Drive rolls can injure fingers C Welding wire and drive parts are at welding voltage during operation keep hands and metal objects clear 1 Electric shock can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 1582 Page 9 2 2 Rating Label For CE Products For label location see Section 4 4 JD Cf 11 50 60 Hz IP 21 O U 10
25. eek ead ee uwa Taas Ata O aa AMA ses 156 354 MOTOR gear 1 8hp 24VDC 272RPM consisting of Jes 9 M1 156353 MOTOR gear 1 8hp 24VDC 500RPM consisting of asses d RE OE DE 153 491 KIT brush replacement consisting of 1 1 AA bel es As OE ARE 153492 CAP brush u ll sun EES aaa ee Ek 2 sat ssl nash Beara NG MAGNG 158 493 Lu BRUSH Carbon ese se see ie gah Be baled ie ETES ER ad 184 136 KIT brush holder replacement 1 1 AO SEA EE ETS 155 098 KIT cover motor gearbox consisting of liste EE OE EE 153 550 COVER motor gearbox consisting of 1 1 EERS MEE ET Nas 155099 iis GASKET COVER o u guy a naibaba aaa dl bga os vere 155 100 SGREW COVER S ics desea ee acy dad en Raa tusa ee nt D Gan D tte alitas 154 081 SPAGER locating 0na pawa aou mu me dr de e AN AE Tecan ated 133493 RING ring ext 250 shaft grv x 025thk 1 1 atch PLM tes cette RE ALS 182414 WASHER flat 1 1 EE MEE EE 182415 PIN cotter hair Ps seed sae EC ER id OE 137 248 SPRING indicator Vos RTS aaa ee 602082 SCREW mach stl rdh 8 32 x 500 dio Er deen ENE RA 602 200 WASHER lock stl split No 8
26. il est bien ventil ou en Ka Hane a portant un respirateur alimentation d air Demander toujours un e Toujours v rifier la terre du cordon d alimentation V rifier et s assu surveillant d ment form de se tenir proximit Des fum es et des rer que le fil de terre du cordon d alimentation est bien raccord la gaz de soudage peuvent d placer l air et abaisser le niveau d oxy borne de terre du sectionneur ou que la fiche du cordon est raccord e g ne provoquant des blessures ou des accidents mortels S assu une prise correctement mise la fees ie rer que l air de respiration ne pr sente aucun danger e En effectuant les raccordements d entr e fixer d abord le conducteur e Ne pas souder dans des endroits situ s proximit d op rations de de mise la terre appropri et contre verifier les connexions d graissage de nettoyage ou de pulverisation La chaleur et les e V rifier fr quemment le cordon d alimentation pour voir s il n est pas rayons de l arc peuvent r agir en pr sence de vapeurs et former des endommag ou d nud remplacer le cordon imm diatement s il est gaz hautement toxiques et irritants endommag un cable d nud peut provoquer une lectrocution e Ne pas souder des m taux munis d un rev tement tels que l acier e Mettre l appareil hors tension quand on ne l utilise pas galvanis plaqu en plomb ou au cadmium moins que le rev te e Ne pas utiliser des c bles us s endommag
27. peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn Y H L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT a e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s y E e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques 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 LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage Fan
28. socket G Contact closure to A completes 24 volts ac contactor control circuit Circuit common for 24 volts AC circuit 10 volts dc output to remote control with respect to socket D Remote control circuit common 0 to 10 volts dc input command signal from remote control with respect to socket D Voltage feedback 0 to 10 volts dc 1 volt per 10 arc volts n T m O0 O O 0 gt Current feedback 0 to 10 volts dc 1 volt per 100 amperes The remaining pins are not used OM 1582 Page 13 4 6 Wire Type Size And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard All 023 To 5 64 in 0 6 To 2 mm 50 To 780 ipm 1 3 To 19 8 mpm Standard All 3 32 To 7 64 in 2 4 To 2 8 mm 50 To 700 ipm 1 3 To 17 8 mpm Standard All 1 8 in 3 2 mm 50 To 300 ipm 1 3 To 7 6 mpm be All 023 To 5 64 in 0 6 To 2mm 92 To 1440 ipm 2 3 To 35 6 mpm 4 7 Motor Start Control To change wire feed starting speed proceed as follows Turn Off wire feeder and welding power source Remove wrapper 1 Front Panel Front panel shown open for illustra tion purposes 2 Left Side Inner Control Panel It may be necessary to remove pan el to access Motor Start Control Remove panel only as far as re quired if options are attached to panel 3 Motor Board PC1 4 Motor Start Control Poten tiometer R70 Turn po
29. using this unit with certain older style Miller CV power sources a weld current sensor Part No 160 963 must be used Power sources include the Deltaweld prior to Serial No KG141349 and the Dimension prior to Serial No KC253517 Wire feeder power is on displays light up but unit is inoperative Check welding gun trigger leads for continuity and repair leads or replace gun Schedule A Wire Feed Speed works but Schedule B Wire Feed Speed does not work or is erratic DIP Switch S1 1 on Option Interface Board PC70 must be in the On position see Section 4 10 Wire Feed Speed Meter display does not match actual wire feed speed Set DIP Switch S2 on Meter Board PC60 in Inches Minute mode see Section 4 10 Actual arc voltage display on meter is held after trigger is released or arc volt age does not change while welding Set DIP Switch S2 on Meter Board PC60 in Voltage Monitor mode see Section 4 10 OM 1582 Page 20 Notes OM 1582 Page 21 SECTION 7 ELECTRICAL DIAGRAM
30. 0V 1 750 A X100 U 24 V 4 10 0A ST 178 794 A 2 3 Symbols And Definitions Note Some symbols are found only on CE products Amperes V Volts ING Alternating Current X Duty Cycle e H Z Hertz U 1 Primary Voltage olo Wire Feed Trigger j die Line Connection Output Jog Ga PG U 2 Load Voltage GJP Trigger Hold On a Press To Set Trigger Hold Off Continuous Weld G Spot Weld Spot Weld Time SE Purge eeeel G 0 D Burnback Time Preflow Time Postflow Time A Read Instructions ht n67 PE yA Increase 4 Primary Current l Rated Current OM 1582 Page 10 SECTION 3 INTRODUCTION 3 1 Specifications Type of Input Welding Power Wire Feed Wire Diameter a IP Overall Weight Power Source Type Speed Range Range Rating Rating Dimensions g Standard 50 To Length 32 in 780 ipm 1 3 To 023 To 1 8 in Dia 872 ahay 24 Volts AC Constant Voltage CV 19 8 mpm 0 6 To 3 2 mm POL eee Single Phase DC With 14 Pin And bue sipag wiati 18i 2 10 Amperes Contactor Cantal Optional High Max Spool 100 Duty 457 mm 35 kg 50 60 Hertz Speed 90 To Weight 60 Ib Cycle Height 14 in 1400 ipm 2 3 To 27 kg 356 mm 35 6 mpm 4 1 Site Selection al 1 Wire Feeder Pa 2 Lifting Eye 3 Rubber Feet 4 Slot Choose slot that allows al
31. 3 ka PAP wa t N gu Wi ss EP 5 aro 5 Es se ag E RC5 5 gt gt 5 a 85 g5 En s S 588 x 2o 9 amp 3 a AN A 82882 1 EE TA A A A 5 one PC60 nad 10 ce Roas amp PC40 a gf bese EE N 2 7 DIGITAL boat 23 v RC63 SEE NOTE 3 RC64 2 gt gt lt lt RC43 5 CONTROL 2 299 sir Ro5 2 lt lt RC62 2 cee riced I EN OPTIONAL SES 2223 5 RC64 3 gt gt 2 LE Rc43 4 Ds 2 s2 RC5 3 gt RC62 4 DIGITAL METER I I FOR RO PLG RC41 2 Ke BEes 5 I l BOARD OPTIONAL RC64 4 gt gt lt RC43 3 SEE NOTE 1 RC42 2 gt gt e552 Res 6 gt Y lee Rc42 3 gt 2 8585828 las Resa s gt gt lt RC43 2 gt eee Rc5 7 gt lt Rc62 5 3 9 RC42 1 gt gt 9 9 RC64 6 gt SIL pas Rosa gt VY I V f 55 Ed ELECTRIC amp WARNING SHOCK HAZARD OM 1582 Page 22 Figure 7 1 Circuit Diagram NOTE 1 WHEN DIGITAL VOLTAGE CONTROL IS USED WITH A CONVENTIONAL POWER SOURCE MAKE THE FOLLOWING CONNECTIONS AT PC40
32. 8 3 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 8 3 Panel Front w Components Fig 8 2 Item 21 ler R1 2 073 562 POTENTIOMETER C sltd sft 1 T 2W 10K ohm Wire Feed Speed A 2 O EE ae ee 149 654 PANEL front se ee ee ee ee ee ee E dd ee ee ee ee ee 1 EA EIE IE 136 339 COVER opening meter not used with digital display option 2 gp AT 134 209 NUT speed push on type 250 2 Dr LED A tic puros 179203 LED 5100 2 0V 20MA green 2 RS tat 172 825 DIGITAL DUAL SCHEDULE RH consisting of 1 Pan act aida OE 173 748 DIGITAL DUAL SCHEDULE LH consisting of 1 ce AS Sac RE N 134 209 NUT speed push on type 250 1 5 LED71 81 179 203 LED 5100 2 0V 20mA green 1 Sac PLG68 48 131204 CONNECTOR 8 SOCKETS ng a NALANG PLG72 131054 CONNECTOR 8 SOCKETS 1 a hess R76 77 86 87 603 856 POTENTIOMETER WW sltd sft 10 T 2W 10K ohm Wire Feed Speed B Voltage Control B 2 6 S71 81 150 982 SWITCH PB MC SPDT 6A 125VAC Press to Set 1 EERS aoe T q Bathe 1539321952 2x NUT TACO as la lcd 1 O EE EE Bake 150 981
33. B spool 1 EE RE ME 071 730 TUBING stl 875 OD x 12ga wall x 2 375 1 fe NO BREL 135 205 NUT stl siflkg hex reg 625 11 w nylon insert 1 ae WS Sete q us bo 141 411 SUPPORT spool 1 en AA 142 838 BRACKET mtg spool RH 1 Me ME PTA 134 306 FOOT rubber 1 250dia x 1 375 high 4 pan 14 Re un ait 13922674 BASE ice EE N N RR EE a 1 dak TOs ci ME Lu Fig 8 5 WIRE DRIVE ASSEMBLY RH 1 E ir RE at 159 647 INSULATOR motor clamp 2 Ree AGE KT mila hd 159 360 INSULATOR screw machine 8 ca EE GELE 602 009 SCREW cap stl sch 250 20 x 1 250 2 Hs oe ER Drae 156 243 CLAMP motor top 44 42 2 EE OT 083 639 WEATHERSTRIPPING adh 125 x 1 500 order by ft 1ft OA HARE SERE 159 646 CLAMP motor base 2 N OO te IR 145 639 STRIP buna N compressed sheet 062 x 4 000 x 4 000 2 Scheie AE E 143 152 SCREW cap stl sch 250 20 x 5 000 LH only 2 AE EDE 139 752 SPACER stl 500 OD x 12ga wall x 3 750 LH only
34. C C Visit our website at www MillerWelds com Miller The Power of Blue OM 1582 138 593X September 2001 Processes MIG GMAW Flux Cored FCAW Gas and Self Shielded Submerged SAW Description E El Wire Feeder Use with CV Power Sources OWNERS MANUAL 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 T RU E Bl lil E tradition They re just as committed to providing equipment and service oR WARRANTY YI that meets the high standards of quality and value established in 1929 Working as hard as you do This Owner s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products Please take time to read the Safety precautions They will hassle free warranty in the help you protect yourself against potential hazards on the worksite We ve business made installation and operation quick and easy With Miller you can coun
35. D 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 7 00 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 Call 1 800 4 A Miller or see our website at www MillerWelds com to locate 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 sovice and Mapai Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Sch
36. DIP switch S3 to the ON position down Spot Time Range Selection Option Interface Standard Settings ER Long Spot Time 0 5 Seconds lt gt ON NORM R27 Or y 330 ON USENSE 7 Short Spot E E Time T 2 I 0 2 5 Seconds X Means switch can be in either position B Means switch must be in this position Digital Meter Functions Standard Standard High Speed High Speed Motor Motor Motor Motor Inches Minute Meters Minute Inches Minute Meters Minute I BE E e H lt lt j I ha Or NG ol Or a is EG I I H n 2 s 1 Voltage Sensing Function P Arc Voltage Sensing Using Arc Voltage Sensing Using Feedback From Welding Voltage Sensing Lead Power Source ent o lt HF I I DIP Switch S3 DIP Switch S3 Set To OFF Set To ON Tools Needed CARO 1 4 in Ref 143 259 G Ref SA 146 866 B Ref SA 148 666 E Ref SA 150 588 D OM 1582 Page 17 SECTION 5 OPERATION 5 1 Front Panel Controls _ O s Lo ol o eo 10 10 1 Voltmeter
37. DUAL SCHEDULE 71 RC31 PLG31 Pale lt 1 lt RC79 1 OPTIONAL lt 1 gg lt ROSA RC35 PLG3S lt Ro31 1 lt cn mole I p K ag gt am 3 3 RC79 3 3 LED71 RC72 1 gt 1 r r f 1 FED Les pieza lt RC31 8 Foy lt Ro31 8 lt RCI1 8 REE J PG mm 90 l o o ZTE lt Res1 7 PREFLOW lt resi 7 post CE lt Ro11 7 AS s71 PRESS 97 I POSTFLOW y OPTIONAL fa ARANA 80 lla E To SET lt 6 6f lt RC31 6 SPOTTINE lt RC31 6 TRIGGER HOLD lt RO11 8 14 4 4 a 79 BURNBACK 55555 70 70 21 wire FEED lt 2 2 lt RC31 2 TRIGGER HOLD lt RC31 2 RC31 PLG31 lt RC11 2 Do PD 106 SPEED B y t r 60 60T Fes sel lt Rc31 5 RC31 PLG21 lt rosi s ROSS PLOSS lt ms pcso 21 P a RIGHT s o 50 23 lt 3 lt RC31 3 RC35 PLG3S lt RC31 3 lt RCI1 3 104 7 m alt mom RUN IN 40 4 lt 4 lt RoM 44 j D dle Rea 2 lt RC11 4 CONTROL y 5 BR nl 5 g OPTIONAL 30 304 1 Ki 1G lt R31 18 2 2 2 r18 g lt RCI1 1 evi 4 VOLTAGE l Y VY Y yJ y y PC10 Ron pLoze ca Pip ol 9o 3 ao BURNBACK RC79 PLG79 1ol110 GP ON SPOT OFF OPTIONAL 2 PC70 70T w s31 32 S31 RC11 PLG21 RIGHT 30102 A are 4 vy ee 21177 gt cae 28 TRIGGER TRIGGER ES HOLD OFF CONT HOLD ON Ja SENSOR OPTIONAL AA nl l RE72 PL672 1022 1e lt cw A A 4 A 122 1 1 H RC75 PLG86 PLG68 REW e ND nm RC98 14 gt 4 lt RC76 PLG76 OL A EF Z kL Lay RC70 PLG70 RC78 PL678 L SEE NOTE 2 _J
38. NCED 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 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 AN
39. a ble r sistant au feu cuir ou laine et une protection des pieds N TH LE SOUDAGE peut provoquer un i incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels 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 tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas dimpossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit 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 so
40. a Health amp Safety Code Section 25249 5 et seq OM 1582 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Symbol Usage Arc Welding Hazards 1 4 1 2 TABLE OF CONTENTS 1 3 Additional Symbols for Installation Operation and Maintenance 1 4 1 5 1 1 1 2 1 3 1 4 1 5 SECTION 2 DEFINITIONS 2 1 Principal Safety Standards EMF Information SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION Signification des symboles Dangers relatifs au soudage al arc Dangers suppl mentaires en relation avec l installation le fonctionnement etla maintenance Principales normes de s curit Information sur les champs lectromagn tiques Warning Label Definitions 2 2 Rating Label For CE Products 2 3 3 1 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 SECTION 5 OPERATION 5 1 Symbols And Definitions SECTION 3 INTRODUCTION Gun Recommendation Table Specifications SECTION 4 INSTALLATION Site Selection Equipment Connection Diagrams Rear Panel Connections 14 Pin Plug Information Wire Type Size And Feed Speed Capabilit
41. ag CT ad ASS 8 8 RC98 13 gt RC79 PLG79 PLETT q Rcss 10 gt gt F4 lt lt Rc75 3 3 E RIGHT 89 l ros Z lt lt Rc75 2 2c 2 QL 9 l NI RC9B 1D SI K RC75 1 2T Mopnonat NGg l RC9B 8 gt gt i p Rea8 755 Z ZZ lt lt RCTB 2 R N 65 _ RC76 6 Rc98 12 gt gt ROTSE 3 NOTE 2 USED WITH FOLLOWING OPTION 42 ka RCSB 11 gt gt lt RC7E S DIGITAL VOLTAGE CONTROL ag 2a ROAD RC9B 5 gt gt lt RC7B 1 1 oR 9o RC76 2 gt gt RC98 2 gt gt russe Rctoo PLG100 BOTES gt DIGITAL METERS WITH LINE lt 1 seca a REMOTE DIGITAL CONTROL RC76 1 72 lt 3 lt 1 lt 3 lt RC79 3 99 Plego LEFT ie ee CEPT Ga Pa Pais a bad lia 2 8 ABR 9 9 5 5 es lt lt sl lt lt RC79 5 OPTIONAL S 2 8 2 2883838 8 8 3 WT E E E E EE EEE E E E 90 RC72 2 gt 2 YY YY YY Y Y Y YY VW lt 2l lt lt 2 lt RC79 2 7 LED81 ie r NG 7 Yo Yo V als RC72 1 gt 1 Y Y 6 5 eg 2 2 E so BELEEF sol ooze 5 kurt Aric AKA AL OO q 1 PRESS a AT PAASA so 80 227 io ser pa Se pada rol re EE G y BORDE PARA ba ka sojle b PC80 1252 N LEFT 50 so Ng RUN IN o 4o SEE VOLTAGE A VOLTAGE A CONTROL NOTE 2 CONTROL CONTROL OPTIONAL 30 s po FOR PORN LEFT CW RIGHT CW RC71 20 Su CONTROL Ras R75 RC76 PLG76 ers 5 po i RC79 PLG79 10 190445 4 vos rez rer WG PC70 70T cw BET VE VA Vs V2 Vee 3 ED oser Pie Y VY Y Y la BES INTERFACE 30 2 3 el lz 52 las se sg z g
42. axstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 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 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 EXPERIE
43. cil a conclu Laccumulation 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 con clusions 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 OM 1582 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos 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 c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 DEFINITIONS 2 1 Warning Label Definitions A Warning Watch Out There are possible hazards
44. e input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes 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 conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring r
45. elding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 1582 Page 3 1 5 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 t
46. ent de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipement 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 dinterferences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 1582 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut
47. eplace 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 som nd 4 98 e A gt si 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 e lf 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 Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e 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
48. 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 exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e 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 e 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 e 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 if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 1582 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 a welding helmet fitted
49. han 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 committee s 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 1582 Page 4 1 Keep cables close together by twisting or taping them 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 Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION AF Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesures a prendre pour viter tout danger som _nd_fre 4 98 1
50. he 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 80 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 Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer x x 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids M
51. is compressed Install gun Lay gun cable out straight Cut off This setting will generally give the best end of wire Push wire through guides up to performance for these types of wires drive rolls continue to hold wire Press Jog button to feed wire out gun To adjust drive roll pressure hold nozzle If necessary move hub and spool support so wire runs straight from the spool through the drive rolls Install wire spool Adjust tension nut so wire is taut when wire feed 3 l Tee Pressure Scale Adjust about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If contact tip is completely blocked wire should slip at the feeder see pressure adjustment above Cut wire off Close cover Install wire guides and anti wear guide Install drive rolls Tools Needed CE D 3 16 5 64 in E Y 15 16 3 8 in NONCONDUCTIVE NONCONDUCTIVE SURFACE SUREACE 2 7 No Wire Slip Wire Slips Ref ST 156 929 A Ref SC 150 922 Ref ST 156 930 S 0627 A OM 1582 Page 16 4 10 Optional Equipment DIP Switch Settings 2 If wire feeder is equipped with a voltage sensing lead set DIP switch S3 e to the OFF position up If wire feeder is NOT equipped with a voltage sensing lead set
52. l rubber feet to sit securely on top of welding power source 5 6 Wire Spool Reel Gas Cylinder Customer Supplied Welding Power Source Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip Ref ST 152 468 A ST 152 566 B OM 1582 Page 11 4 2 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires Roughneck C Series Guns 300 400 500 And 600 Amp FCAW Self Shielding Wires FC 1260 Or FC 1150 4 3 Equipment Connection Diagrams 10 R N Oo WD 8 Welding Power Source Contactor Control Power Cord Positive Weld Cable Negative Weld Cable Workpiece Gun Wire Feeder PSA 2 Control Optional Use with welding power sources supplying 115 volts ac power 9 Gas Hose 10 Gas Cylinder 152 616 C 152 615 C OM 1582 Page 12 4 4 Rear Panel Connections 1 Y Adapter Gas Hose Supplied 2 Shielding Gas Valve Fitting Requires fitting with 5 8 18 right hand threads 3 Weld Cable Terminal 4 Jumper Weld Cable 5 Weld Cable 6 Optional Current Sensor Connections 14 Pin Cord Power Switch 9 Rating Label Location o N Tools Needed EL 9 16 5 8 in 3 16 in Ref 800 353 B 4 5 14 Pin Plug Information lA REMOTE 14 Pin Pin Information 24 volts ac with respect to
53. ment 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 slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammable
54. mer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PI CES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des operations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter Vouie Le bruit des processus et des quipements peut affecter louie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser 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 soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou da
55. n D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans Ng e Keep all doors panels covers and guards closed and securely in place 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 If 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 w
56. ns 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 cir cuits 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 Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance gi Risque D INCENDIE OU Pis DEXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces inflammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL
57. ools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA 2000 Miller Electric Mfg Co 6 00
58. 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 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 e 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 r 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 1582 Page 2 a 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 HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equip
59. s e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit a gag OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Z Reduce current or reduce duty cycle before G starting to weld again e Donot block or filter airflow to unit ee STATIC ESD can damage PC boards y e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards SS N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 5 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washingto
60. s de grosseur insuffi ment n ait t enlev dans la zone de soudure que l endroit soit bien sante ou mal piss s ventil et si n cessaire en portant un respirateur alimentation e Ne pas enrouler les c bles autour du corps d air s P aH tous tak metaux Ek Na l ments e Si la pi ce soud e doit tre mise la terre le faire directement avec un Pelventdegager des TUM ES toxiques cn cas Ge soucage cable 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 OM 1582 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur 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 provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc e Porter des v tements de protection constitu dans une mati re dur
61. se only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1582 Page 32 t9 qQ 8 z9 d 10 pasinbay SM Z 9 1280 8 sou BANG Y JO Z UM Buoje GZ x 28 8 MOJOSIOS ZLI 709 M SPIND JeamjuY EZ SHO PUY aping ajeipawlaju aping 1elul Uy SUIEJUON Wy yoga eL Z 90 ovo 80 LSL 96 EL EM 690 IS Z0Z EGO ES LSO ISL LLZ E90 sous 280 ISL 296 ZEL EE 890 IS SOZ 90 EE 0S0 LSL 604 90 za 180 LSL L96 ZEL ui 190 ISL COZ 90 EN 670 LSL OLZ E90 EO 080 LSL 096 ZEL ES 990 IS FOL ESO KI 870 LSL 696 ZEL EI S90 ISL G 804 90 EE 640 LSL SS6 ZEL EI v90 LSL 904 EGO EI Zv0 LSL 06r E80 os 8 0 ISL 966 ZEL EN 90 ISL 04 EGO EN 970 LSL 687 E80 EN ZLO ISL 466 ZEL ES 290 LSL LOZ ESO EN SYO LSL 896 ZEL 350 LSL 190 LSL 000220 9 0 LSL PPO LSL G69 ESO SZO ISL LEO ISL E OEL 480 cO LSL OEO LSL 1104 UN UN 11904 UN UN 1104 UN UN 1104 UN UN BNG MOH HOU PANG NOY HOU PANG 1104 y 1109 lt HA 1104 y 1108 lt 3 A0049 9N JAOOHI9 HA JA00Y9 N JAOOU9 A SHA 9PIN9O SAM Puy 104 SALMO 1 8 SIQEL c03 GV 466 0S1 ww g e LZS 6b 966 OSL LZS 6b 966 OSL 025671 S66 OSI 025671 S66 OSI 025671 S66 0S4 669 ESO EN GEO LSL 869 90 EN vEO LSL 469 90 os 0 LSL EN 681 LOL 004 S0 Ea c 0 ISL 615671 766091 615671 766091 815671 E66 091 BIS 6v E66 091
62. t on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a REGISTERED QUALITY SYSTEM Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in i ich exact part ne USA abe 2g edo will then help you to decide which exact p the ISO 9001 Quality System you may need to fix the problem Warranty and Panaad service information for your particular model are also provided Miller offers a Technical Manual which provides pp more detailed service and parts information for your A unit To obtain a Technical pa Manual contact your local w AE distributor Your distributor can also supply you with Welding Process Manuals A such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line g 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 catalog 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 Miller The Power of Blue 44 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer Californi
63. tentiometer clockwise to in crease time it takes the motor to ramp up to speed Remove protec tive white rubber cap before making adjustment Adjust potentiometer R70 using a small nonconductive screwdriver Reinstall left side inner control pan el if it was removed Reinstall wrapper Tools Needed Non Conductive EE k ERK CA 1 4 in Ref 143 259 G Ref SB 183 121 C OM 1582 Page 14 4 8 Rotating The Drive Assembly gt gt Remove screws 6 from front edge Fi gt of wrapper and loosen screws on lt back edge of wrapper 1 Front Panel 2 Drive Assembly Rotation Adjustment Opening 3 Drive Assembly Tools Needed 3 CO 1 4in 3 16 in Ref 143 259 G Ref ST 153 093 A OM 1582 Page 15 4 9 Installing And Threading Welding Wire Be sure that outlet cable has proper size F For soft wire or small diameter stainless liner for the welding wire size When steel wire use 2 drive rolls and set drive installing gun position liner extending roll pressure from 0 to a maximum of 4 from outlet wire guide as close as pos on the pressure indicator scale so that sible to drive rolls without touching only the inner spring
64. ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de VAssociation canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques ll y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin 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 Re search Coun
65. udage 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 e Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e 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 re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES Se 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 vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 1582 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fer
66. uer Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension des que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous avec la pi ce a souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique 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 tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entra nement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres LES FUM ES ET LES GAZ peuvent moyens isolants suffisamment grands pour emp cher le contact phy tre d sique ventuel avec la pi ce ou la terre etre dangereux
67. with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material 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 e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or
68. y Table Motor Start Control Rotating The Drive Assembly Installing And Threading Welding Wire 4 10 Optional Equipment DIP Switch Settings Front Panel Controls 5 2 Overload Protection And Optional Side Panel Controls SECTION 6 MAINTENANCE AND TROUBLESHOOTING Routine Maintenance 6 1 6 2 Troubleshooting WARRANTY SECTION 7 ELECTRICAL DIAGRAM SECTION 8 PARTS LIST Q Q A O1 O1 O1 N Declaration of Conformity for European Community CE Products Note 37 This information is provided for units with CE certification see rating label on unit Manufacturer s Name Miller Electric Mig Co Manufacturer s Address 1635 W Spencer Street Appleton WI 54914 USA Declares that the product D 64 conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Arc Welding Equipment Part Welding Power Sources IEC 60974 1 September 1998 Second Edition Arc Welding Equipment Wirefeed Systems IEC 974 5 September 1997 Draft Revision Degrees of Protection Provided By Enclosures IP Code IEC 529 November 1989 First Edition

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