Home

Miller Electric Axcess User's Manual

1. 3 1 Specifications Type of Input Welding Power Wire Diameter Welding Circuit Overall Power Source Type Wire Feed Speed Range Range Rating Dimensions Welghi 40 Volts DC Axcess Series Standard 40 To 1400 ipm 1 0 030 To 1 8 in 100 Volts Length 27 in 686 46 Ib 10 Amperes To 35 6 mpm 0 8 To 3 2 mm 750 Amperes mm 20 9 kg 1007 HUY Width 12 1 2 in Max Spool Cycle 318 mm Weight 60 Ib 27 kg Height 14 1 2 in 368 mm 4 1 Selecting A Location Do not move or operate unit where it could tip Tipping Location Do not stack units Beware of tipping Lifting Forks Use lifting forks to move unit A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Extend forks beyond opposite side of unit 2 Hand Cart Use cart or similar device to move unit 3 Rating Label Use rating label to determine input power needs INPUT SERIAL NO STOCK NO QE 4 VOLTS Locate unit near correct input AMPERES d power supply PHASE S Line Disconnect Device loc 2 3 96 Ref 803 502 A OM 211 076 Page 9 4 2 Connection Diagram OM 211 076 Page 10 Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative Weld Cable Workpiece Voltage Sensing Lead Optional 0 NOU POND 7 Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable
2. 1 VO A ludis Oe 134 834 HOSE SAE 187 ID x 410 OD order by ft 2ft OM 211 076 Page 36 Item Dia Part No Mkgs No Description Quantity Figure 9 3 Drive Assembly Wire Fig 9 1 Item 4 continued sed a NE 184 685 ADAPTER ASSY gun feeder LH including WE EER KON ER 149 959 FITTING brs barbed M 3 16tbg x 312 24 1 MEL EE a oa E 179265 syss ADAPTER QUISER 29 reser SG die ei ob ee ae 1 N NEE N E 604 538 WASHER flat stl SAE 312 1 AE PETER 151 437 KNOB plstc T 1 125 lg x 312 18 x 1 500 1 TEL A tet 185 624 SCREW 010 32 x 0 50 hexwhd 40D stl pld slffmg trilob 2 N OE EE FEE 601 872 NUT stl hex full fish 375 16 1 Lugd EG ESTE 602 213 2 WASHER lockst SPIL 375 1i ir e Ro ien ee Ree 1 TE EE 602 243 WASHER flat stl std 375 1 M c AE EN 601 966 SCREW cap stl hexhd 375 16 x 1 250 1 EL DE EE 108 940 SCREW cap stl hexhd 250 20 x 750 4 Dee N EN 179 263 COVER drive roll consisting of 1 EE DT HE 178 937 LABEL warning electric shock EET e E d Recommended Spare Paris THave nearest Factory Authorized Service Agent replace encoder To maintain the factory
3. ERR UNKN e The unknown error indicates a malfunc tion in the system somewhere Press Jog Purge button to clear error OM 211 076 Page 27 7 3 Troubleshooting A Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but electrode wire is not energized Check and secure weld cable connections see Section 4 2 Electrode wire feeding stops or feeds erratically 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 6 Change to correct size drive roll see Table 9 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 feeder power is on displays light up but unit is inoperative Check welding gun trigger leads for continuity and repair leads or replace gun OM 211 076 Page 28 Notes OM 211 076 Page 29 SECTION 8 ELECTRICAL DIAGRAM 4 WARNING Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e
4. replace cord immediately if damaged bare wiring can kill 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place e Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e Turn Off inverter disconnect input power and discharge input capacitors accordin
5. Description i ES Wire Feeder OM 211 076H 2006 06 Mill Processes gt er MIG GMAW Welding Axcess Wire Feeder OWNER S MANUAL Visit our website at File Advanced Manufacturing Systems KW www MillerWelds com ams We aw e From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir U E BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Deeds EE pio EE You e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Wl 00012000 of reliable service with proper maintenance And if for some reason
6. Ref 801 915 Ref 803 501 A 4 3 Rear Panel Connections And Rotating Drive Assembly Ee e 1 9 Pin Network Receptacle 2 Shielding Gas Valve Fitting Requires fitting with 5 8 18 right hand threads Connect customer supplied gas hose 3 Weld Cable Terminal 4 Weld Cable 5 Drive Assembly 6 Drive Assembly Rotation Knob 7 Rating Label Location To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob Tools Needed I 9 16 5 8 in I 3 16 in 802 825 A 803 503 A OM 211 076 Page 11 4 4 9 Pin Network Receptacle Information 7 ES LE G Pin Pin Information A Capacitor C1 to ground B Shield C Volt sense D Can low E Can high F 24 volts dc common G 24 volts dc H Motor voltage 40 volts Motor voltage 40 volts 4 5 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires 400 500 And 600 Amp Air Cooled Guns GMAW Pulse Water Cooled Guns OM 211 076 Page 12 4 6 Installing And Threading Welding Wire Install wire spool Adjust tension nut so Install wire guides and wire is taut when wire feed stops anti wear guide Install drive rolls TET dl Pressure Indicator fo ini TEEN TN Tools Needed eds 3 16 5 64 in E p 15 16 3 8 in Drive Rolls po Cable End Of Liner
7. See Section Program 5 4 O Process O Wire Type Gas Type Section Section 5 9 5 8 Trigger Control O Trigger Hold a Feeder Set Up Section 5 7 Section Section OM 211 076 Page 17 5 4 Program Push Button 5 5 Upper Display n E Program AT 2 1 Program Display The number of the active program is displayed 2 Program Push Button 3 Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob Momentarily press button to lluminate LED To change the program number rotate Adjust knob to select one of eight programs Pressing and holding the push button will display current wire size wire type and process To reset feeder to factory settings turn power source off for 10 seconds Press and hold button in on power up wait until top display shows RST and bottom display shows NO before releasing button Feeder Set Up button LED will begin flashing Turn Adjust knob to change bottom display to show YES then press Feeder Set Up button to confirm selection The top display will show CYCL and the lower display will show PWR Turn welding power source power off for 10 seconds then turn power back on again ne H nn v Volts 1 Upper Display The upper display shows voltage or arc length The unit displays both preset voltage or arc length and actual voltage When welding actual arc voltage is displayed 2 Upper Display
8. Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly 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 replace
9. TDS allows the operator to select between a pair of weld programs by using the gun trigger In TDS mode momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected weld programs TPS allows the operator to select weld programs by using the gun trigger In TPS mode momentarily pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total of 8 programs Eight active slots for selection of various processes wire type and parameters A selection made for MIG Pulse Accu pulse and RMD optional CV weld process with individual settings of voltage and wire speed Conventional pulse program using peak background pulse width frequency and peak voltage as factory taught data Adaptive method is controlled by frequency adjustment Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds Adaptive response is controlled by peak and minimum current levels Benefits are shorter arc lengths better puddle control more tolerant of tip to work variation less audible noise no arc wandering allows weld to fill in at toes increasing travel speed and deposition and more tolerant to poor fit up and gaps CV Pulse process designed for high travel speeds Typically used in Robotic applications Arc is de signed to be tight and fast Front panel display is ACCU SPED CV Pulse process using a pulse waveform with modified curves at
10. Wire Feed Speed LED LED illuminates to indicate the preset wire feed value is being displayed and can be adjusted using the Adjust knob 3 Amps LED LED illuminates to indicate the average amperage is being displayed while welding and for 3 seconds after welding is terminated The amperage must be above a minimum value of 25 amps for this function to operate 4 Arc Ctl Arc Control LED LED illuminates to indicate that inductance MIG or ARC Pulse Accu pulse or RMD optional is being displayed and can be adjusted using the Adjust knob 5 Time LED LED illuminates to indicate that a time value is being displayed for a sequence function and can be adjusted using the Adjust knob 6 Lower Display Push Button 7 Lower Display Push Button LED Pressing the button illuminates the LED and selecis either WFS or Arc Cil value for changing using the Adjust knob To select Arc Ctl press and hold lower display button for 2 seconds The top display will show either INDU for a MIG program or ARC for Pulse Accu pulse or RMD optional To exit Arc Ctl or INDU either press the upper display push button or press and hold the lower display push button for 2 seconds o di During a welding program operation it is possible to change WFS wire feed speed by using the Adjust knob regardless of the active program sequence that appears on the dis play When the Arc Ctl LED is illuminated it is possible to change values while we
11. snap in nyl 1 375 id x 1 750 mtg hole 1 sc VOERE ace 057 357 BUSHING snap in nyl 937 id x 1 125 mtghole 1 TE aes RE das 211018 CONNECTOR circ 97 met 9 pin size 20 rcpt 1 ree PLG43 46 49 Te shina 115093 HOUSING PLUG SKTS service kit 1 EE EE ce 137 761 NUT 750 npt 1 31 hex 27h nyl blk 1 Tu OOR EED ER a Wa 219 047 VALVE 40 VDC 2 way custom port 1 8 orf w frict 1 IE HE IE 134 201 STAND OFF SUPPORT pc card 4 en nexo Ra ed 097 132 STAND OFF SUPPORT pc card 4 EER AE ab 211002 ENCLOSURE Control Eie E REA EE Ie EN EM do EIS 1 id ees POZ auis 212 493 CIRCUIT CARD ASSY motor filter llle 1 18 EEN 213 632 SWITCH rocker dpdt 10A 250VAC 20A 30VAC on none on 1 sign PET visse 212459 CIRCUIT CARD ASSY trigger filter 1 AO DRE ACA cus tidos 048 282 RCPT W SKTS service kit 1 9 5 AE ER EE 211 OBS ce GC ME e GENEE 1 OM 211 076 Page 34 Item Dia Part No Mkgs No Description Quantity Figure 9 2 Control Box Fig 9 1 Item 21 Continued EE ae ke eg 211 073 6 NAMEPLATE OWEN rd RE Opi PEU ee Ee ELES GA ed a 1 n EG 210 998 SWITCH ASSY jog purge including 1 redire S2 raie 200 29
12. Californie chapitre 25249 5 et suivants procr ation Se laver les mains apr s manipulation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de DES ORGANES MOBILES peuvent provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es a enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e 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 interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner
13. Have only qualified persons install SHOCK HAZARD use or service this unit CAN vi SHIELD CAN L 24 COMMON N M A PURGE 1 lt 13 12 T JADE EE ES 1 H 3 sss PC6 J10 2 gt 24 COMMON 4 MOTOR CONTROL 410 57 CAN H PB MICROPROCESSOR 410 1 JOG CAN L J1 PLG40 910 4 gt MED gt J2 PLG42 J10 3 gt RC4 1 gt PC gleich 1 J10 PLG43 Er TRIGGER Ei ROLLE Ro1 2 gt BER DEE di De RC1 3D gt 44 J15 o J13 PL645 RC4 4 gt RC1 7 ee 4 J14 PLG46 J15 PL647 sys ZECIRODE SENSE 37 1 sd AE AAA 5 J16 PLG48 va z 13 J17 PLG50 Y I den 5 aC LE __ ER J14 5 gt gt aa 2 1 4 o dS Ke J14 7 gt Her a 24 GAS VALVE 35 19 J12 12 NTT 36 id EE lt J12 5 e e E E res VAN VAN MOTOR MOTOR 40VDC Figure 8 1 Circuit Diagram OM 211 076 Page 30 PC7 BB gg DISPLAY MODULE KX45 43 PLC72 RED 15 ZA 14 BLACK WHITE BLUE BARE ELECTRODE SENSE A NE A RCBO 1 FILTER RC80 PLG80 lt lt RCB1 4 RC81 PLG81 RC82 PLG82 AAA A A A A A A A _ QQ _ o RC83 PLG83 PC51 TACHOMETER PICK UP MOTOR HOUSING CHASSIS RG1 G RC1 F RC1 E RCI D RC1 B RO 1 0 RG TI RC1 H RC1 A OM 211 076 Page 31 SECTION 9 PARTS LIST 7 Hardware is common and not available unless listed 21 Fig 9 2 803 506 C Figure 9 1 Main Assembly OM 211 076 Page 32 Item
14. 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 e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit IX FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Put on grounded wrist strap BEFORE handling boards or paris e Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury e Keep away from moving paris e Keep away from pinch points such as d
15. Press Jog Purge button to clear error ERR MOTR e The motor error indicates that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle Press Jog Purge button to clear error ERR WFS e The wire feed speed error indicates actual wire feed speed does not match wire feed speed command Press Jog Purge button to clear error ERR STRT e The start error occurs if the user has the trigger held for more than 3 seconds without striking an arc or if a valid arc voltage and current is not detected The 3 second arc start error time can be changed using an op tional PDA with File Management software OM 211 076 Page 26 Indicates a temperature error Indicates a wire stuck error ERR STOP e The stop error occurs as result of obstructions in the wire feed system or a faulty wire drive system Check wire feed and wire drive systems Press Jog Purge button to clear error ERR FLOW e The flow error indicates no gas flow to the gun The error may be reset by reestablishing gas flow to the gun and then pressing the Jog Purge button ERR COOL e The cool error indicates no coolant flow in water flow switch option The error may be reset by reestablishing coolant flow to the gun and then pressing the Jog Purge button ERR GND e The ground current error occurs if weld current is detected in the earth ground connection May be ca
16. adjust setting pressing the lower display push button a second time will cause either volts or arc adjust to appear on the display Use the Adjust control to set either parameter If the sequence has a wire feed setting pressing the lower display push button a third time will cause wfs to appear on the display Use the Adjust control to set wire speed parameter e Press the lower display push button a fourth time will cycle the display back to time e Press the Feeder Set Up button a second time to go to Trigger Control mode and allow the top display to become active Use the Adjust control to cycle through trigger control methods as follows dual schedule trigger hold trigger dual schedule program select 4T see Section 5 1 The lower display will show the current state of each trigger control method as being either on or off Not all trigger control methods are compatible with each other and turning on certain functions will cause other trigger functions to turn off Press the lower display push button to allow the bottom display to become active Use the Adjust control to turn selected trigger control methods on or off If trigger hold is set to on the trigger hold LED will illuminate Note if 4T is set to on trigger hold will automatically be set to on since this parameter is necessary for the 4T function e Press the Feeder Set Up button a third time to cycle back to standby mode 1 Adjust Control T
17. l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une 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 e Veiler ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement 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 Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de cables blindes l utilisation de filtres de ligne ou la pose de protec t
18. optional this control will affect the in much the same way as inductance In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second provided no other changes are made and increase the arc on time The increased arc on time makes the welding puddle more fluid Control knob used to change or set parameters and functions OM 211 076 Page 15 General Terms Sequence Preflow Start Crater Postflow Feeder Set Up Auto Thread 5 2 Power Switch OM 211 076 Page 16 Selecting Sequence will allow setting of preflow start crater and postflow times and parameters Setting a time value for gas flow prior to arc start Provides voltage arc adjust wire feed rate and time value for modified arc starts which is only adjustable with the optional PDA with File Management WaveWriter software Allows setting of voltage arc adjust wire feed rate and time value for arc ends Setting a time value for gas flow after arc end Allow selection of Sequence and trigger functions Method of jogging wire without holding jog or trigger switch Pressing Jog and Retract simultaneously will automatically feed wire Default setting is 192 at a feed rate of 700 ipm these values can be changed using a PDA with File Management WaveWriter software Pressing jog purge or trigger switch will terminate the auto threading feature 1 Power Switch 803 504 A 5 3 Front Panel Controls
19. shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e If 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 A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines 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 gt Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of Calif
20. the unit needs repair GUALITY 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 AUS ba adio 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 Miller Welds com on the web 7 Miller Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad anloro USAGE EEN 1 152 Are Welding e EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings iis EE EE Ee ee eke Ge eke ee ee ee ke eee ee 3 1955 Prili tpal Salel Standards es curn de ee pated BED ieee Verr MEE de te RAND DEE END a 4 156 EMF Iniormalien rita d i Dar ti Red A Sc ed DAC Ed V d is 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS TEEN 5 2 2 Dangers relatifs au soud
21. 20 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 B m 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 som 3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes NN Nr Ce groupe de symboles signifie Avertissement Attention Risques 2 1 4h Symboles utilis s Symbole graphique d avertissement Attention Cette pro c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints A Indique un message de s curit particulier d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer IF 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 e V rifier fr quemmen
22. 5 SWITCH rocker spdt 15A 12V on off on 1 ED LU E ES 131056 HOUSING PLUG SKTS service kit near 131052 HOUSING PLUG SKTS service kit Wo ME EE EE 179 851 KNOB pointer 1 670 dia x 250 id push on w spring 1 2 EERS 216 866 FILTER ASSY sense lead including 1 ES RR E 216 696 CAPACITOR w terminals 027UF cR 038 855 BLOCK term 20 amp 2 pole screw term 1 DORT AD un 224 383 RESISTOR w terminals 2 K 5 watt d OE EN E 216 872 CABLE volt sense 7in e 1 AA OE SEEN IE 213 004 4 CABLE volt sense EENG EE ou PLG47 115 094 HOUSING PLUG SKTS service kit T PLG48 202592 HOUSING PLUG SKTS service kit MEE DOE PLG4 136 810 HOUSING PLUG SKTS service kit eb EER ed PLG81 115 092 HOUSING PLUG SKTS service kit EE EE PLG10 130203 HOUSING PLUG SKTS service kit EE PLG50 136 810 HOUSING PLUG SKTS service kit e ie PLG44 131 058 HOUSING PLUG SKTS service kit Sein ae PLG45 188 352 HOUSING RCPT SKTS ser
23. 7 Be sure that outlet cable has proper size CS For soft wire or small diameter stainless 7 To adjust drive roll pressure hold nozzle liner for the welding wire size When steel wire reduce drive roll pressure on about 2 in 51 mm from nonconductive installing gun position liner the rear roll to half that of the front rolls surface and press gun trigger to feed wire extending from outlet wire guide as against surface Tighten knob so wire close as possible to drive rolls without does not slip Do not overtighten If con touching tact tip is completely blocked wire should slip at the feeder see pressure adjust Install gun Lay gun cable out straight Cut off ment above Cut wire off Close cover end of wire Push wire through guides up to drive rolls continue to hold wire Press Jog button to feed wire out gun Ref 156 929 A Ref 150 922 Ref 156 930 802 954 S 0627 A OM 211 076 Page 13 4 7 Feeder Display At Power Up Lu Program NEN Volts Time Arc Adjust 1 Upper Display 2 Lower Display e NEN O Amps Arc Ctl 2 Process Sequence Wire Type O Trigger Control Gas Type Trigger Hold e Process Set Up j Feeder Set Up Power Source Upper Display Lower Display Voltage Range 300 450 675 4 8 Dual Schedule Switch Option 1 Maint 2P Maintained Contact 2 Pole Switch DSS 9M Part 041 793 1 DSS 9M 1 OM 211 076 Page 14 SECTION 5 OPERATION 5 1 Operational Terms The follo
24. 71 76 86R 409 90 Argon 10 COs C10 ag 98 Argon 2 O OX2 Aluminum ALUM 4XXX 5XXX 10096 Argon ARGN Notall wire types may be available with your unit OM 211 076 Page 21 5 10 dog Purge Pressing the Jog Purge switch allows the operator to jog wire without energizing the weld power or gas valve circuit e The unit provides the ability to jog the wire feeder by means of the gun trigger or the Jog Purge switch If the welding arc does not initiate in 3 seconds after the gun trigger is activated the unit will perform a jog operation for a maximum of 30 seconds If the gun trigger is still activated after 30 seconds the jog operation is terminated to prevent complete unspooling of the wire in the case of a damaged gun The unit OM 211 076 Page 22 displays the ERR STRT message to inform the operator that the trigger is activated e Jog speed can be adjusted by the Adjust control when the unit is jogging wire The unit displays jog speed when the unit is being jogged e Jogging can also be accomplished by pressing the Jog Purge button e Pressing the Jog Purge button also allows the operator to purge gas lines before 1 Jog Purge Push Button 2 Adjust Control 3 Gun Trigger Receptacle 803 505 A welding and to preset gas pressure at the regulator This unit is equipped with Auto Thread capability By rocking the switch from purge to jog within 0 5 seconds will automatically feed wire fo
25. Cem use ad 1 po E Fig 92 s CONTROL BOX SEER eres atc ette XR ee a e Ax eese del 1 OD TER POUR En 216695 CAPACITOR w terminals 027UF 1 Recommended Spare Parts 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 211 076 Page 33 7 Hardware is common and not available unless listed 803 507 D Figure 9 2 Control Box Item Dia Part No Mkgs No Description Quantity Figure 9 2 Control Box Fig 9 1 Item 21 TOS ME 134 464 LABEL Warning General Precautionary 1 ERG IE EE SET 212 781 WRAPPER feeder su AE ae rt er DO Ne eue 1 OM EE EE TN 211 164 PANEL pc card switch overlay including e FREE AE EE 210 655 NAMEPLATE overlay 1 it bats PES insat 227 879 CIRCUIT CARD ASSY switches 1 AD aas PO ae 204 049 CIRCUIT CARD ASSY display micro w program 1 E TE NE OE GAN 212 808 BAFFLE PG MOUNTING carita GS Ae anne ECC Enc wor a Sew eo Se We det 1 7 PC6 209681 CIRCUIT CARD ASSY motor Control 1 dr Br ee EE TT 211003 ENGEOSURE MOLOI ir ie SE BUS etre eee team E E cts 1 TI prre 010 494 BUSHING
26. 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 United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller
27. 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 1910 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 INTRODUCTION
28. Part No No Description Quantity Figure 9 1 Main Assembly ea ER EE 159 647 INSULATOR motor clamp 1 Seet EROS 159 646 CLAMP motor base 1 E EET 159 360 INSULATOR screwmachmne RR RR II 4 Fre Fig 9 3 DRIVE ASSEMBLY wire 1 Brusen OR et tee 141 753 HUB amp SPINDLE ASSEMBLY consisting of 1 Ds EE ct 058 427 RING retaining spool 1 7 ee a 180 571 SHAFT support spool verse m e e eee 1 TET 010233 SPRING cprsn 970 OD x 120 wire x 1 250pld 1 EES teme 057 971 WASHER flat stl keyed 1 500dia x 125thk 1 DO uia cina chr 010 191 WASHER fbr 656 ID x 1 500 OD x 125thk 2 ng vo er 2 058 628 5 WASHER Drake stl ns eet td eme CAT ek erba tec n e DES 2 V2 ie iek deut udi d 058 428 RUB SPOT beoe deed 1 LE t te teh 135 205 NUT stl slflkg hex reg 625 11 w nylon insert 1 E DEER 200 556 SUPPORT spoel cerrara tex on kel Sc E ee A 1 ELE EED 201 781 KNOB w extension clamp 1 10 ENE eee 156 243 CLAMP motor OD ddnde aco tto etes ith ce t deer oe Mile Ses 1 NE AE ENE IR 145 639 STRIP buna N compressed sheet 062 x 4 000 x 4 000 1 p cU 200 552 BASE quai cbr A edd e DEN NG 1 UE iicet pere 134 306 FOOT rubber 1 250 dia x 1 375 high no 10 screw 4 TEEL EN 200587 2 STIFFENER DAS es une Le E eir E
29. Push Button Press the button to illuminate the LED and allow changing information in the display Release button to display voltage 3 Upper Display Push Button LED The upper display push button LED OM 211 076 Page 18 Arc Adjust illuminates to indicate that information displayed can be changed by the Adjust control 4 Volts LED Weld Voltage In MIG 5 Arc Adjust LED Pulse Mode The LEDs below the display illuminate to indicate which value is being shown At any time while welding the unit permits the adjustment of the weld voltage and overrides the display of actual arc voltage To activate Carbon Arc Cutting CAC press and hold the upper display push button in on power up CAC will appear on the upper display and NO will appear on the lower display Rotate adjust knob to YES on the lower display and press the flashing Feeder Set up push button CYCL will appear on the upper display and PWR will appear on the lower display Turn welding power source off and back on again to enable the Carbon Arc Cutting process selection 5 6 Lower Display 5 T e Time ues a ln T WFS o E Ctl 1 Lower Display The lower display shows WFS wire feed speed AMPS amperage ARC CTL arc control or Time The feeder displays only preset wire speed at idle not welding While welding the average amperage is displayed The lower display shows welding sequence time when the Time LED is illuminated 2 WES
30. ady for a weld sequence Press Jog Purge button to clear error MOTR COM e The motor communication error indi cates motor board lost data communica tions Press Jog Purge button to clear error PLS WAIT e The uim communication error indicates user interface board lost data communications Press Jog Purge button to clear error OVER CRNT e The over current error indicates welding power source primary current is too high Check and correct input power Press Jog Purge button to clear error LOW WFS e The low wire feed speed error indicates actual wire feed speed is lower than wire feed speed command Check for obstructions in the wire feed system or a faulty wire drive system Press Jog Purge button to clear error E STOP e The emergency stop error occurs if the user presses an emergency stop button Reset the emergency stop button and press Jog Purge button to clear error RMD DONE e The RMD done error indicates the RMD demo is completed Press Jog Purge button to clear error Indicates a low WFS command error Low e wes Indicates an emergency stop error OVER AVER e The over average error indicates that cur rent is outside the average range for the set program parameters Check and correct program parameters Press Jog Purge but ton to clear error REL TRIG e The release trigger error indicates the user held the trigger when starting a weld program Press Jog Purge button to clear error
31. age Parc 2 5 2 3 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 aa simus ads Gate dates tae cds BEE Gant oe DAL Ae 8 2 6 Information EMP 4244 Gas nes EER nda cds REX EER WED RD E R Se ei 8 SECTION 3 INTRODUCTION ooo press EE De EED rue EE ON wie De Gakuen RE ie redere 9 ds lu OD CIICAIOAS EE 9 SECTION 4 INSTALLATION 32x Bam Y oux Ex ad 9 As 5elecuhgA Losatlo sapeca rara enc dp APS apie ew ead Mo DEE ODE EE KAAR 9 4 2 Cones Dagia aar AS DE eu sed AD SAS OE Nat eT 10 4 3 Rear Panel Connections And Rotating Drive Assembly 11 4 4 9 Pin Network Receptacle Information EE EE EE EE EE GE nr EE ee se mnn 12 4 5 Gun Recommendation Table v EE ee eae DE A EE Lee DS ie es 12 4 6 Installing And Threading Welding We 13 4 7 Feeder Display AUPOWer UD EE EE WS AR EE EA 14 4 8 Dual Schedule Switch Option 14 SECTIONS OPERATION nine E HE Rates ductae Necesse BE OE SEGE DES ES raw de SG ie wees 15 5 1 Operational Ters siese sone ser od he nel ich od were BEE GE fn ea te vs m ae 15 9 25 Power SWINGIN ass AE rd e RE ceeds ee de nnd ste wen Ns a OE Rd 16 5 3 Fon Panel ontrolS uad ve elt aces ih ee RO e S Cw RR OE A ete 17 5 4 Pro
32. arranty 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 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 otate 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 Heplacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2006
33. d 1 2 Arc Welding Hazards 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 m ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the weldi
34. d Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magnetiques et lectriques Le courant de soudage pendant son passage dans les cables de souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs 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 211 076 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org telephone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American
35. ds 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 e 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 e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches d
36. e levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du cote oppose de l appareil L EMPLOI EXCESSIF peut SUR 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 e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes PC 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 provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage AN 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de
37. es recouvrir soi gneusement avec des protections homologu es e Ne pas souder dans un endroit ou des tincelles peuvent tomber sur des substances inflammables e Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites gel es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans
38. eurs dans la zone de travail Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation OM 211 076 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ins 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 P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 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 an
39. g 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 e 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 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 while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 211 076 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense v
40. gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou e 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 e 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 et les d graisseurs situations l utilisation d un poste souder DC a 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 e Couper l alimentation ou arr ter le moteur avant de proc der veillant diment forme de se tenir a proximite 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 oxygene 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 e
41. gram Push BUON a xo uoa ann oe ner ER EN SUE ES et Ce Sica TS eel 18 5 6 Upper DISDIAV os seven ain ao ca ta REEDE Rae ee a de tane HOE e 18 5 6 Lower DISDIBy c eS ser EE hd ce m bake EER ea ce ead dee ie DR op free Sd is EE e 19 5 7 Feeder Set Up Push BURON sas uus xu ehe o ka De nes ORO ER Ca e ao ac ae es 20 5 8 Adjust Control wn axe ehh dtes eo e tare GO Ce BOO EE 20 5 95 Process Een Push BUOM sss ox xa ERES A E QUO DRR E an ET co bats d 21 DO JO LUTO REPE 22 DESCON sien end sions oe RENE N ME GOS RE Ee SE OR ER Ge 23 SECTION 6 SETTING SEQUENCE PARAMETERS se ese ese ese kaak sek sek sek sek nnn 24 6 1 Sequence Parameters In Program 24 SECTION 7 MAINTENANCE sas nmn A A A cede eer eee 25 75 Routine Maintenance xem ade ee a e EE RD DUE wk GE voc doo aC ia LR A 25 1 2 O A EE EER E E RE KIE a EDE IL D 26 1 9 OUDIGSHOOUNG cux pm Ce RE REI ER AS E GE DM EE DR OE EE ean DOE EED SE p A 28 SECTIONS ELECTRICAL DIAGRAM ss ad RES oe ee A RR RR en 30 SECTIONS PARTS EET SE Sk Ene AR ER care AS EE 32 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage r 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 7 Means Note not safety relate
42. handed 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 e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve
43. he Adjust control is used to change various sequence parame ters and to select various se quences Hefer to the section for the function in question for informa tion related to using the Adjust con trol 5 9 Process Set Up Push Button 1 Process Set Up Push Button 2 Process Set Up LED Process 3 9 wire Type O Gas Type Program Selection LEDs Process Set Up e Press the Process Set Up push button the make a selection rotate the Adjust control If a custom program is loaded using an first time will illuminate the button LED and Process LED above the button Both displays will show the current process and if desired these displays will be active to allow selecting a new process Default processes are MIG PULSE and ACCU PULSE Pressing the Process Set Up push button a second time will illuminate the Wire Type LED and the bottom display will show wire types available for the selected process To make a selection rotate the Adjust control Pressing the Process Set Up push button a Pressing the Process Set Up push button a fourth time will illuminate the Gas Type LED and both displays will show available gas selections for the process and wire type and wire size selection To select an item rotate the Adjust control Pressing the Process Set Up push button a fifth time will load the program that matches the selected parameters process wire type wire size gas The upper display will show PROG and the l
44. inguisher 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 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 e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E 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 211 076 Page 2 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 Do not touch hot parts bare
45. ique avec la pi ce couper ou le sol une m me borne de sortie de soudage Il reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou la ou on risque de tomber LES FUM ES ET LES GAZ peuvent e Se servir d une source lectrique courant lectrique UNIQUEMENT si etre dangereux le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n Le soudage g n re des fum es et des gaz Leur cessaire se servir de la fonction de t l commande si l appareil en est inhalation peut tre dangereuse pour la sant quip e D autres consignes de s curit sont n cessaires dans les conditions e 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 Alint 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
46. isible 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 e 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 T 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 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 ext
47. lding by using the Adjust knob To return to actual values on the display exit the Arc Ctl display 7 The lower display push button has additional functions when entering the sequence and trigger control functions see Section 5 7 OM 211 076 Page 19 5 7 Feeder Set Up Push Button 1 2 O Sequence O Trigger Control old ad O Trigger H OO q Feeder Set Up Feeder Set Up Push Button Feeder Set Up Push Button LED Press button to choose sequence trigger control or trigger hold 3 4 5 6 5 Sequence LED Trigger Control LED Trigger Hold LED Lock LED Access Allowed Only By Using An Optional PDA With File Management Software When the Feeder Set Up button is pressed while in standby the Feeder Set Up push button LED illuminates and the top display will be active Use the Adjust control to select preflow PRE start STRT crater CRTR or postflow POST parameters Press the lower display push button to allow the bottom display to become active The time LED will automatically begin flashing 8 Adjust Control OM 211 076 Page 20 Preflow Time Time Postflow N Time Welding Sequence Diagram and the unit will be in the time mode Initially all sequences will appear as off Use the Adjust control display time and enable the time sequence Setting a time automatically enables a sequence To turn off a sequence change time setting to OFF If the sequence has a voltage or arc
48. ment at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE 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 w
49. n 25 CO Accu pulse 045 Mild Steel 90 Argon 10 O2 Pulse 052 Mild Steel 90 Argon 10 CO MIG 052 Mild Steel 75 Argon 25 CO Program 1 Program 2 Program 3 Program 4 Program 5 Program 6 Program 7 Program 8 Trigger Control Gas Type Trigger Hold A Feeder Set 7 Reset mode is not active when Program Lock is enabled The reset mode allows the operator to reload factory program settings for all eight active programs in the unit 7 System configuration data will be lost during the Reset operation CYCL m E Process Wire Type 6 GasType E Cycl Pwr message appears on the display when programs complete loading 9 Trigger Control Trigger Hold Turn power off wait 10 seconds and turn power back on again to complete the reset operation 7 After Reset is complete be sure to load appropriate programs that contain the correct wire size process and shielding gas for the welding operation 198 993 803 504 A OM 211 076 Page 23 SECTION 6 SETTING SEQUENCE PARAMETERS 6 1 Sequence Parameters In A Program 7 For more information on Sequence mode see Feeder Set Up Push Button in Section 5 7 If time is set to Off in Weld Sequence Parameters sequence welding continues until gun trigger is released Volts Trim IPM Seconds If time is set to zero in any timed sequence except Weld the sequence is skipped 1 Preflo Off 5 0 E 3 Ma
50. ng process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owners 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
51. onal 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 211 076 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 ffom American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 22
52. original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Table 9 1 Drive Roll And Wire Guide Kits mediate i i i Drive Ed een 08mm 160988 wese Tee wrwo oso osm wows wese wws wows 1 o oss 09mm 15006 wesie 181028 089700 181006 072000 151082 wwe f omm romm wowc wese ere osos e in 150995 149520 151029 053699 151039 053706 151055 132955 151 072 053 708 ooo Tamm woes sese Iss es SC in 150 995 149 520 Ma 151040 053704 151057 132960 151073 053 710 3 32 in 094 in 2 4 mm 150 996 149 521 151 041 053703 151 058 132 961 151 074 053709 7 64 in 110 in 2 8 mm 150 996 149 521 151042 053705 151059 132962 151075 053711 Re 159997 149522 NN 151 043 053707 151060 132963 151076 053 712 Each Kit Contains An Inlet Guide Intermediate Guide And 045 233 Antiwear Guide With 604 612 Setscrew 8 32 x 125 Along With 4 Drive Rolls OM 211 076 Page 37 Notes Warranty uestions 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 paris can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The ex
53. ornia to cause cancer and birth defects or other reproductive harm Wash hands after handling OM 211 076 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 ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed 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 Nati
54. ower display will show LOAD optional PDA with File Management software the upper display will show CUST and the lower display will show PROG The Adjust control remains active to allow loading a standard program in place of the custom program e Pressing and holding the Process Set Up push button in on power up allows viewing the software revisions of each circuit board in the system The top display shows the board PCM UIM WFCM and AIM auto mated units only and the lower display shows the last 3 digits of the circuit board part number plus a letter designator Press third time will keep Wire Type LED lit but the upper display will be active and show wire sizes available for the current wire type To the flashing Feeder Set Up push button to exit the screen displays and continue the power up process If no changes were made to any setup items no program will be loaded and unit will return to standby mode Table 5 1 Welding Wire And Gas Abbreviations Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation Steel SIL E70 E100 E120 10096 CO CO2 9096 Argon 1096 CO C10 8596 Argon 1596 CO C15 7596 Argon 2596 CO C25 9596 Argon 596 CO C5 9596 Argon 596 Os OX5 98 Argon 2 Os OX2 Stainless Steel SS 308 309 312 316 98 Argon 2 Os OX2 81Ar 18HE CO Tri Gas Accu pulse 90HE 7 1 2Ar 2 1 2CO Tri Gas MIG RMD Accu pulse Cored Tubular Wire MCOR
55. p les pieces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut e Porter un harnais de s curit si l on doit travailler au dessus du sol provoquer des accidents mortels ou des br lures e S assurer que tous les panneaux et couvercles sont correctement en graves Le circuit de l lectrode et de la pi ce est q H sous tension lorsque le courant est d livr la PAGE NR sortie Le circuit d alimentation et les circuits internes de la machine e 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 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 e Ne pas raccorder plus d une lectrode ou plus dun 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 phys
56. particular locations within the wa veform Has a distinguished change in arc characteristics Front panel display is ACCU CURV RMD refers to Regulated Metal Deposition A precisely controlled short circuit transfer Benefits of RMD are well suited to thin materials improves gap filling and spatter reduction Provides less heat input into workpiece minimizes distortion and allows use of larger diameter wire on thin gauge materials Selection of wire type by alloys and classification Selection of shielding gas being used in application Selection procedure for entering program Enters selected program information into program slot Preset voltage in MIG mode at idle actual voltage while welding and 3 seconds hold value at end of weld Indicates time values being set for timed functions e g Preflow Postflow which are only available in the Arc On and Analog input or the Arc On and No Analog input modes Distance from end of wire electrode to workpiece Term used to represent wire feed speed In MIG mode wire feed setting is independent of voltage setting In pulse Accu pulse and RMD optional adjusting wire feed speed also increases power level on wire electrode one knob control Indicates average amperage while welding and 3 seconds hold value at end of weld Allows setting of inductance in MIG mode In pulse and Accu pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory pulse data In RMD
57. pertise of the distributor and Miller is there to help you every step of the way 7 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 warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or 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 mon
58. r a factory default setting of 192 in 4877 mm of wire before stopping The default feed rate is 700 ipm These settings can be changed using an optional PDA with File Management software Pressing the Jog Purge switch or gun trigger during Auto Threading will terminate the automatic feed operation 5 11 Reset Mode RST Kl Volts 9 Time Arc Adjust Ki wrs 9 Amps Arc Ctl Sequence O Wire Type E Feeder Set Up Enter reset mode by turning power On and pressing the Program Push Button untilthe RST NO message is displayed RST NO message will not display until after the power up sequence is completed approximately 20 seconds BRST Program Volts 9 Time Arc Adjust d Volts 9 Time Arc Adjust Ei WFS Amps ArcCil Sequence 9 Trigger Control o I WFS Amps ArcCil Sequence 9 Trigger Control Trigger Hold Trigger Hold C Q Rotate Adjust knob to change NO to YES Feeder Set Up Press the Arc Control button to confirm the reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the following factory default programs are loaded into the unit Pulse 035 Mild Steel 90 Argon 10 CO MIG 035 Mild Steel 75 Argon 25 CO Accu pulse 035 Mild Steel 90 Argon 10 O2 Pulse 045 Mild Steel 90 Argon 10 CO MIG 045 Mild Steel 75 Argo
59. retaining ext 250 shaft x 025thk 2 EER EE 199990 x PIN DINGE Ls ads beu pat ux t dee Dan dte Ea E se er a ee Re ca EE 1 ds GO Lead MII reise 219 005 MOTOR deal ss as roo ea Aa aida dada 1 RR ele ace DER de 203 631 PRESSURE ARM consisting of d T Osa oe Er EE n 182415 254 PIN COMER NA La Gk nite tinte te EE A Ee ct a Sew nod A Oe 1 Us An 72 203 640 KNOB w extension short pressure arm 1 TT HE 203 641 2 WASHER Tal SUSAENO O ss pad ae ars Ee de RE RS ERR kand ett 2 ar E CRE RA 182156 s a SPRING EDISH pes See 2 RE e et s URS 182155 4 SPRING A eue REN 2 ON N 192 746 cu BUSHING SPIN arta daten ede a E nee 2 e AA RD dee Sea aise 203633 band SAR DS PINO Se iia dob ch ER dne dal 1 so Y oe rM 209 682 sra CARRIER Shall EE Se ase ab ace od oe Ee SE meme dus 1 gt EI 133 739 WASHER flat buna 375 ID x 625 OD x 062thk 2 AR A TE 203 637 KNOB w extension long pressure arm 1 mE EER EN 1229 550 ENCODER quadrature 500PPR incremental 5V shaftless 1 EE MEI 604 311 GROMMET rbr 250 ID x 375mtg hole 062 groove 1 OE DR EI IM D ue 603 115 WEATHER STRIPPING adh 125 x 375 N RE EE atu 167 387 SPACER 1OGAUNG ee 2 poo EE 16802 e DRIVE PINON sosser ee 1 uoc 133 308 RING retaining ext 375 shaft x 025thk
60. revers des bottes et un casque e Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes e 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 pw re e Le soudage l caillement le passage de la piece la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 211 076 Page 6 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 DES PIECES CHAUDES peuvent provoquer 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 e 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 LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de s
61. rive 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 E 3 1 4 California Proposition 65 Warnings STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans 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 e 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 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
62. sur la peau Des tincelles sont projet es pendant le soudage e 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 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 e 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 RIZ 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 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 danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit l
63. t 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 e L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e 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 raie pos de dans la Section 2 5 Lire et e Ne pas enrouler les c bles autour du corps id DUM e Sila piece soud e doit tre mise a la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct nor Shireen ler reparercer apparell e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendantle fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en d m me temps cause de la pr sence d une tension vide doubl e E UNE DECHARGE ELECTRIQUE peut e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le ven entrainer la mort cham
64. t le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d operations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulverisation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute zl E Ge ment toxiques et irritants e Toujours verifier la terre du cordon d alimentation V rifier et s assurer e 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 vanis plaqu en plomb ou au cadmium moins que le rev tement n ait de terre du sectionneur ou que la fiche du cordon est raccordee une t enlev dans la zone de soudure que l endroit soit bien ventil et en prise correctement mise la terre portant un respirateur alimentation d air Les rev tements et tous les e En effectuant les raccordements d entr e fixer d abord le conducteur m taux renfermant ces l ments peuvent d gager des fum es toxi de mise la terre appropri et contre v rifier les connexions ques en cas de soudage OM 211 076 Page 5 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 nere des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et
65. ths after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns
66. timulateur cardiaque rester distance e 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 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 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 Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccor
67. used by a conductor making contact with unit chassis Check and repair feeder weld connections Press Jog Purge button to clear error Indicates an arc stop error FLOW Indicates a gas flow error ARC Indicates an arc error LINE Indicates a line error ERR STUK e The stuck error occurs if the welding wire sticks to the workpiece at the end of a weld May be caused by poor weld conditions The error may be cleared by cutting wire from workpiece and pressing the Jog Purge button ERR TEMP e The temperature error indicates welding power source has overheated and shutdown The error may be cleared by allowing unit to cool down and pressing the Jog Purge button ERR LINE e The line error indicates input power is outside of unit operating range Check and correct input power Press Jog Purge button to clear error ERR ARC e The arc error indicates an arc outage occurred possibly from a wire feeder error or power source error Check wire feeder and power source Press Jog Purge button to clear error 7 2 Diagnostics Continued Indicates a weld cycle wait error Indicates an overcurrent error Indicates a UIM communication error Indicates a motor communication error AVER TRIG uwen Indicates an over average current error Indicates an arc error Indicates an unknown error Indicates a trigger closed error WELD WAIT e The weld wait error indicates unit was not re
68. vice kit ET PLG42 131 054 HOUSING RCPT SKTS service kit ccm PLG40 201665 HOUSING RCPTPLUG SKTS service kit PTT 207 676 STAND OFF no 6 32 x 250 lg 250 hex 2 Hecommended Spare Parts 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 211 076 Page 35 7 Hardware is common and not available unless listed See Table 9 1 For Drive Roll amp Wire Guide Kits 802 950 B Figure 9 3 Drive Assembly Wire Item Dia Par No Mkgs No Description Quantity Figure 9 3 Drive Assembly Wire Fig 9 1 Item 4 TA MI 010 668 SCREW cap stl sch 250 20 x 1 500 4 ERES Du pM OE DE 172075 CARRIER drive roll w components 4 ao Bash dos Draft 149 962 SPACER carrier drive roll 4 DEC NM RR 149 486 PIN rotation arm rocker 2 T p 132750 ARM DIGSSUTO eu DE pi edt e Sr deor he rtc m ce o m ode 2 E E ER 150 520 SPACER flat stl 257 ID x 619 OD x 105 2 TO NITE 133 493 RING
69. wing is a list of terms and their definitions as they apply to the interface unit in the wire feeder General Terms Arc Adjust Trigger Control DS Dual Schedule TH Trigger Hold AT TDS Trigger Dual Schedule TPS Trigger Program Schedule Program Process MIG Pulse Accu pulse Accuspeed AccuCurve RMD optional Wire Type Gas Type Process Set Up Program Load Volts Time Arc Length WFS Amps Arc Control Inductance Adjust Term used to represent arc length adjustments in pulse programs Increasing Arc Adjust increases the actual arc length Likewise decreasing arc adjust shortens arc length Arc Adjust is replaced by volts in MIG programs Selecting Trigger Control allows activating trigger functions such as DS TH 4T TDS and TPS Dual Schedule allows selecting a pair of programs that can be used together Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger In trigger hold mode momentarily press gun trigger and wire will feed until gun trigger is momentarily pressed again 4T allows the operator to select between weld parameters and crater parameters using the gun trigger Crater time must be set for at least 0 2 seconds to make this function operational If gun trigger is released during welding unit goes into trigger hold then pressing and holding trigger again causes unit to stay in crater until trigger is released and crater parameter times out
70. ximum IPM may actually be lower depending on wire 2 Postflow Off 5 0 size and gas combination 10 0 44 0 40 1400 4 Crater 10 0 44 0 40 1400 Off 5 0 0 99 0 99 X Setting available qto Crater ime qo Start Preflow Tus Postflow Time Time Er qto Time Preflow Start Weld Crater Postflow pes Trigger Trigger Pressed Released OM 211 076 Page 24 SECTION 7 MAINTENANCE 7 1 Routine Maintenance A Disconnect power before maintaining 3 Maintain more often during severe conditions Y Check Change Clean To be done by Factory Authorized Service Agent Replace Reference 8 5 SG x Unreadable Labels Weld Terminals x Damaged Gas Hose X Weld Cables Months dl Mix Cords X Gun Cables X Cracked Parts Every 6 Months Drive Rolls Inside Unit OM 211 076 Page 25 7 2 Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors Explanations are in the text below TACH MOTR us STRT Indicates a motor error Indicates a tachometer error Indicates an arc start error Indicates a wire feed speed error Indicates a coolant flow error Indicates a ground current error ERR TACH e The tach error occurs 2 seconds after the loss of tachometer feedback The motor speed is regulated through the monitoring of voltage and current

Miller Electric Axcess User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents