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Miller Electric 75 Welder User Manual

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1. 1 A payaa 219 132 Screw 375 16x2 00 Hexwhd 81D Pld 1 NN eS eZ 602 241 Washer Flat 281 Idx0 625 Odx 065t Stl Pld Ansi 250 1 EA A musee 181 221 Screw 250 20x 50 Button Hd Soc Stl Pld 1 en 2222 Da OE EIN 092865 v Key SI 12151230 d LA RE 1 E Loue cn 219 084 PressuleASSV di dia dois 1 x deed aia s pd 144 172 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 1 TN aaa ees 219098 2 BOEKE AE 2 m RR 1 TEE EET HT 219 092 sGlamp PIN POMWGL gri uo ee er te oe ie en ane AD 1 ed o ai RADE ee es 219 136 Lock Pin Power 1 O Mes s saus 219096 Knob Tri Lobe W 375 16 Stud 2 500 Lg Blk 1 nci EE 219 125 Screw 010 32x 50 Soc Hd Hex PIN 1 N se LITE 219091 Holder Guide Intermediate 1 AE AE Id 219 129 Screw 010 32x1 50 Soc Hd Hex Stl Pld 2 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 228 956 Page 38 gt Hardware is common and not available unless listed 804 589 A Figure 9 4 Drive Assembly Wire Item Dia Part No Mkgs No Description Quantity Figure 9 4 Drive Assembly Wir
2. E PE EE 179 851 KNOB pointer 1 670 dia x 250 id push on w spring 1 D EERS 216 866 FILTER ASSY sense lead including 1 ES eum e a asna 216696 CAPACITOR w terminals 027UF cR 038 855 BLOCK term 20 amp 2 pole screw term RO deb un 224 383 RESISTOR w terminals 2 K 5 watt PEE 216872 CABLE volt sense7 in AA OE SEEN ANN 219004 46 CABLE volt sense iis rt aod doe tet eed Aen es dta te 7 EE ou PLG47 115 094 HOUSING PLUG SKTS service kit T PLG48 202592 HOUSING PLUG SKTS service kit 1 PTT t PLG4 136810 HOUSING PLUG SKTS service kit d T PLG81 115092 HOUSING PLUG SKTS service kit EE EE PLG10 130203 HOUSING PLUG SKTS service kit 1 EE PLG50 136 810 HOUSING PLUG SKTS service kit 1 DET PLG44 131 058 HOUSING PLUG SKTS service kit 1 TOUS PLG45 188 352 HOUSING RCPT SKTS service kit 1 ET PLG42 131 054 HOUSING RCPT SKTS service kit 1 DE PLG40 201 665 HOUSING RCPTPLUG SKTS
3. Indicates an over RMD DONE e The RMD done message indicates the RMD demo is completed Pressing Jog Purge button will change the screen to CYCL PWR on the display Turn unit power off and back on again OVER AVER e The over average error indicates that current is outside the average range for the set program parameters Check and correct program parameters Press Jog Purge button to clear error 7 3 Troubleshooting average current error Indicates a contactor on error Indicates a CRC PCM bus error UNIT COMM e The unit communication error indicates the data bus on the PCM board is not functioning properly Press Jog Purge button to clear error REL TRIG e The release trigger error indicates the user held the gun trigger after a timed weld was completed causing the contactor to remain on Press Jog Purge button to clear error Indicates a trigger closed error Indicates an unknown error TRIG STUK e The trigger stuck error indicates the user held the gun trigger during power up Press Jog Purge button to clear error ERR UNKN e The unknown error indicates a malfunction in the system somewhere Press Jog Purge button to clear error 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 Check g
4. OM 228 956B 2o06 08 Mill Processes I er MIG GMAW Welding Description cv ES Wire Feeder Axcess AlumaFeed 75 OWNER S MANUAL Visit our website at File Advanced Manufacturing Systems y www MillerWelds com aw 4 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 ete jue ere You e i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And if for some reason the
5. 4 25 RC1 PLG1 DE i 2 oo degt Ge 1 3 gt gt 48 15 3 J13 PLG45 RCA 4 a RCc1 4 gt gt J15 4 J14 PLC46 J15 PLC47 Ly EEUTUDE SENSE 37 D 5 J16 PLG4B E lt 1413 13 J17 PLG50 V 13 5 Haas TACH COMMON 31 18 lt 13 14 J44 5 gt TACH A 32 EE TACO AIV g SEWE BE GAS VALVE lt J12 12 CAS WW J5 AAS VALVE B aL lt J12 5 T RON 5 5 5 RCE M NM MM 40VDC Figure 8 1 Circuit Diagram OM 228 956 Page 32 a J4 2 Fe Be gg DISPLAY MODULE EE ND i M I 45 1 E 15 28 2 14 BLACK WHITE BLUE BARE ELECTRODE SENSE FILTER C1 RC80 PLG80 an lt lt RC81 4 RC81 PLG81 A RC82 3 gt AE RC82 1 gt WHITE TAGHOMETER PICK UP CHASSIS PCB1 MOTOR HOUSING ZS m 1A 1 12 RC1 G RC1 F RC1 E RC1 D RC1 B RC1 C RC1 RC1 H RC1 A 211 005 D OM 228 956 Page 33 SECTION 9 PARTS LIST gt Hardware is common and not available unless listed 4 Fig 9 3 9 4 21 Fig 9 2 804 588 A Figure 9 1 Main Assembly OM 228 956 Page 34 Item Part No No Description Quantity Figure 9 1 Main Assembly M de Dr As 159 647 INSULATOR motor clamp 1 FEE N 159 646 CLAMP motor base 1 TEMP 159 360 INSULATOR screw machine 4 T T Figures 9 3 9 4 DRIVE
6. OO NOU POND gt Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable Ref 801 915 Ref 804 584 A 4 3 Rear Panel Connections And Rotating Drive Assembly 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 4 Weld Cable Screw Screw Size 375 16 x 1 50 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 0 to 350 Amps weld connection Tools Needed C 9 16 5 8 in 3 16 in 804 586 A OM 228 956 Page 11 4 4 9 Pin Network Receptacle Information Pin Pin Information REMOTE 9 Capacitor C1 to ground Shield Volt sense Can low Can high 24 volts dc common 24 volts dc T oO MI O O D gt Motor voltage 40 volts Motor voltage 40 volts 4 5 Installing Drive Rolls Pressure Assembly Door Drive Roll Ejector Button Drive Roll Carrier Installation Open pressure assembly door Align drive roll slots with three lobes on drive roll carrier Insert drive roll onto carrier Drive roll will snap into place Removal gt Remove PD wire guide before removing lower drive rolls Lift up drive roll swing arm and press eje
7. Press Jog Purge button to clear error UNIT MEM e The unit memory error indicates the PCM board lost memory data Press Jog Purge button to clear error UIM MEM e The uim memory error indicates user interface board lost memory data Press Jog Purge button to clear error MOTR MEM e The motor memory error indicates motor board lost memory data Press Jog Purge button to clear error WELD WAIT e The weld wait error indicates unit was not ready for a weld sequence Press Jog Purge button to clear error communication error Indicates a memory CRC UIM error Indicates a memory CRC PCM error Indicates an overcurrent error LOW WFS Indicates a low WFS command 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 7 2 Diagnostics Continued _uNkw Indicates RMD demo is done
8. des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner 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
9. respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situes proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute zl E Ge ment toxiques et irritants e Toujours v rifier 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 raccord e 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 228 956 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 n re des rayons visibles et invisibles int
10. 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body 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 A a W z Ce groupe de symboles signifie Avertissement Attention Risques 2 1 4 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 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 a prendre pour supprimer gt Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr
11. A Ee ae A 18 s Power SMIC ne de N se De Ota th de i EE OD RD SE hu S EGO DE do Ge b 1 19 5 3 Front Panel Gontrols sui qm ndr EE ade Rd re De E We ee O eR GEE RE masus as 20 5 4 Program Push BUON ue coe etant A gc SE Laien tede Latt 21 55 UPper RE os TZ aco ha a dt aad ee ito AREA RE ches debated eat SA DR deis oid id 21 5 6 ewer BET EE 22 5 75 Feedsr e Push BUMOHa s sx zu acu xam ERE REA dE EXE E EPUM Ped means 23 90 A A UPRET 23 5 9 Process oet Up Push BUON enu mx ete then RR RR ta PE REDI fe DEOR da 24 De OO EO AA AA o woe Ent EE Ed os EE LE OE da RR 25 Seis Reset Mode od webbe he Dea So us a fo t RD dos SR EE ERA SA tata ed 26 SECTION 6 SETTING SEQUENCE PARAMETERS se ese sees ese kak ae kak ae Rek sek ae se 27 6 1 Sequence Parameters In A Program 27 SECTION 7 MAINTENANCE 1 99 ao EET a Ree biensur etais 28 7 1 Routine Maintenahte EE 28 ER es ie EE AD IA de Sa curd Ms 29 1 9 droubleshOoling estados BEER ces a rs etis So EEN DE gn GR 31 SECTION 8 ELECTRICALDIAGRA Mica ia A A ER SR EE ES 32 SECTION 9 PARTS LIST is DE ADA OEA DES DE DOER DR OS DE AE 34 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in th
12. ASSEMBLY wire 1 D Gawd RR S Qasa oss 141 753 HUB amp SPINDLE ASSEMBLY consisting of 1 E ETE 058427 RING retaining spool 1 rp dec 180571 SHAFT support spool 1 bis Eet ie 010233 SPRING cprsn 970 OD x 120 wire x 1 250pld 1 e EE 057 971 WASHER flat stl keyed 1 500dia x 125thk 1 MO leet das se 010 191 WASHER fbr 656 ID x 1 500 OD x 125thk 2 ble e acta e 058 628 WASHER brake stl 2 le AAA 059 420 HUB SDOOI ia de 1 TOE EDE ou 135 205 NUT stl slflkg hex reg 625 11 w nylon insert 1 A es 200 556 SUPPORT spoel 14i xe Ce c tex on kel dan E ee A 1 EET iah ts 201 781 KNOB w extension clamp 1 EE N 228 131 CLAMP molor lOD sudes lr BENE tee to ree DE de t decet bdo eS 1 A EES N 145 639 STRIP buna N compressed sheet 062 x 4 000 x 4 000 1 e ARE EE 200552 BASE ata RE A SH ck es Se ae Sale De ie 1 e dein gae 134 306 FOOT rubber 1 250 dia x 1 375 high no 10 screw 4 EO AS mois sie 200 557 STIEFENER DaS es sue ES Mee e 1 sa 2 WEE Figure 9 2 CONTROL BOS 1 A A dis 216695 CAPACITOR w terminals 027UF 1 Recommende
13. 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 OM 228 956 Page 21 5 6 Lower Display e Time Hs a k WFS K CH 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 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 OM 228 956 Page 22 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 illumina
14. BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies
15. 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 Preflow Time Time Postflow x 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 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 goto Trigger Control mode and allow the top display to become active Use the Adjust control to
16. Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipm
17. and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2006 Miller Electric Mfg Co 2006 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller
18. circ 97 met 9 pin size 20 rcpt 1 nes PLG43 46 49 L wees 115 093 HOUSING PLUG SKTS service kit 1 Ed 605 227 NUT 750 14 knurled1 68dia 41h nyl 1 Tu Ke AA 219047 VALVE 40 VDC 2 way custom port 1 8 orf w frict 1 dass 134 201 STAND OFF SUPPORT pc card 4 x urine 097 132 STAND OFF SUPPORT pc card 4 or Osos tire 211 002 ENCLOSURE COMO uuu sl llu da rias 1 ris POZ A 212493 CIRCUIT CARD ASSY motor filter 1 18 EEN 213 632 SWITCH rocker dpdt 10A 250VAC 20A 30VAC on none on 1 is l9 PET ss 212459 CIRCUIT CARD ASSY trigger filter 1 AO DRE ACA sidia 048 282 RCPT W SKTS service kit 1 E D ma aza atas DEK 211 085 ce GC ME e GENEE 1 OM 228 956 Page 36 Item Dia Part No Mkgs No Description Quantity Figure 9 2 Control Box Fig 9 1 Item 21 Continued EE ae litis Chat 228 270 2 NAMEPLATE IOWeD di sti eds 1 ee EE 210998 SWITCH ASSY jog purge including 1 redire S2 raie 200 295 SWITCH rocker spdt 15A 12V on off on 1 EE 131 056 HOUSING PLUG SKTS service kit dt AT OER a 131 052 HOUSING PLUG SKTS service kit
19. disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes 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 228 956 Page 1 ARC RAYS can burn eyes
20. 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 displays the ERR STRT message to inform the operator that the trigger is activated e Jog speed can be adjusted by the Adjust g Sp y 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 for 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 OM 228 956 Page 25 5 11 Reset Mode Volts 9 Time Arc Adjust WFS 9 Amps ArcCtl Sequence O Wire Type Gas Type Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed RST NO message will not display until after t
21. lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling OM 228 956 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 1
22. protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans 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 e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 228 956 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 PI CES 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 lure
23. service kit 1 EE 207 676 STAND OFF no 6 32 x 250 lg 2b0hex 2 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 228 956 Page 37 gt Hardware is common and not available unless listed 8 See Table 9 1 For Drive Roll amp Wire Guide Kits 9 10 804 186 A Figure 9 3 Drive Assembly Wire Item Diagram Part No marking No Description Quantity 9 3 Drive Assembly Wire 9 1 Item 4 TX qc 224 12 Drive Assy Mechanical Lh 1 o O ER 219 126 Screw Shld Stl Sch 375 16 X 500 X 1 000 Shld 2 TE qu 219 098 Insulator Base Mtg Components 1 de de nue 108 943 Screw 250 20x1 50 Hexwhd 61D Gr Pld 1 DT TP 219133 Screw 375 16x1 50 Hexwhd 81D Pld 1 SN OMNE 093 664 Gear Spur Insulated Drive 1 ME Te EEN 079 625 Washer Wave 500 Idx0 750 Odx 015t Stl Lbs 1 END us EN 605 308 Ring Rtng Ext 500 Shaft X 035 Thk 1 EK a PPP a us 601941 Screw 250 20x1 75 Hexwhd 61D Gr Pld
24. shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e 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
25. 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 PSF e The primary power error occurs if the primary power circuit inside the feeder is not functioning correctly Check feeder connections Press Jog Purge button to clear error OM 228 956 Page 29 7 2 Indicates a line error Indicates a temperature error wen WAT Indicates a weld cycle wait error Indicates a memory CRC motor error 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 OM 228 956 Page 30 Diagnostics Continued ERR ERR UNIT UM ARC POL MEM MEM Indicates a polarity error Indicates an arc error Indicates a motor Indicates a UIM communication error ERR POL e The polarity error indicates the polarity is different than the selected polarity Check and correct weld cable connections
26. 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 STL E70 E100 E120 100 CO CO2 90 Argon 10 CO C10 85 Argon 15 CO C15 75 Argon 25 CO C25 95 Argon 5 CO C5 95 Argon 5 O OX5 98 Argon 2 O gt OX2 Stainless Steel SS 308 309 312 316 98 Argon 2 Oo OX2 81Ar 18HE 1C0O gt Tri Gas Accu pulse 90HE 7 1 2Ar 2 1 200 gt Tri Gas MIG RMD Accu pulse Cored Tubular Wire MCOR 71 76 86R 409 90 Argon 10 COs C10 299 98 Argon 2 O OX2 Aluminum ALUM 4XXX 5XXX 100 Argon ARGN Not all wire types may be available with your unit OM 228 956 Page 24 5 10 Jog 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
27. 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 SU oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web ur Miller Mil_Thank 2005 04 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol RE e EE 1 1225 Arc Welding Hazards ue ide nd aed ne A ag ne mao DEE ER miel 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 95 Prin ibal Sale Standards uet C RC RR A A AI Ta 4 EO EMPERO MAA csi exa CR CE A AA SAD EE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2515 SOV ITO OOS USE Ses der Bt odes re ir meme ed u
28. when programs complete loading Trigger Control Trigger Hold Turn power off wait 10 seconds and turn power back on again to complete the reset operation After Reset is complete be sure to load appropriate programs that contain the correct wire size process and shielding gas for the welding operation 198 993 804 587 A SECTION 6 SETTING SEQUENCE PARAMETERS 6 1 Sequence Parameters In A Program Sequence Parameters 10 0 44 0 40 1400 4 Crater 10 0 44 0 40 1400 Off 5 0 0 99 0 99 X Setting available _ iP Start Preflow Time Time M ri Preflow Start Weld Crater Trigger Trigger Pressed Released For more information on Seguence mode see Feeder Set Up Push Button in Section 5 7 If time is set to Off in Weld sequence welding continues until gun trigger is released If time is set to zero in any timed sequence except Weld the sequence is skipped gt Maximum IPM may actually be lower depending on wire size and gas combination Postflow Time i cl Time Postflow Sequence End OM 228 956 Page 27 SECTION 7 MAINTENANCE 7 1 Routine Maintenance Disconnect power before maintaining y Check Change Clean x Replace Reference To be done by Factory Authorized Service Agent LES e ZI LS 4 e B vi e Every 3 x Unreadable Labels Weld Terminals x Weld Cabl
29. 2202 4102 t l phone 703 412 0900 site Internet Www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci a propos de tels champs Cependant apres 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 lt Laccumulation de preuves suivant le jugement du comit na 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 228 956 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org t l phone Intern
30. 7 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 228 956 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York 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
31. OT PARTS can cause severe burns Do not touch hot parts bare 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
32. Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 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 f 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 Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can cause injury e Keep a
33. a oou mutet te T oru d ee 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2 5 Principales normes de s curit 8 2 5 Intermallon EME ora se ies Di entendons uen eo ed de o 8 SECTION 3 INTRODUCTION EE 9 9 1 SBOGHIG3IIORNS 3 ee NN OON REO RNC E RA OR E RE RE E 9 SECTION 4 INSTALLATION e Eeer ai a P RE O A A Kien SE 9 45 Selecting A LOCA ON AI A O at DE ES GR OS e 9 4 2 Connection RT ele BEEN 10 4 3 Rear Panel Connections And Rotating Drive Assembly 11 4 4 9 Pin Network Receptacle Information 12 4 5 Installing DEIVe ROIIS usos RN a ER e RU IUE A xut ave Du 12 4 6 Installing PD Continuous Wire Guides 13 4 7 Installing Non PD Old Style Wire Guides 14 4 8 Installing Ee at MEET 15 4 9 Installing Welding Wire And Adjusting Pressure Drive Setting 16 4 10 Feeder Display At Power Up RR HH y ae asqa 17 4 11 Dual Schedule Switch Options i 17 SECTIONS OPERATION os fatness carck ESE ROK OE REED OE OR eee eee EH 18 9 1 Operational Terme ses asus AE ewe OL DE EOD RED eee en Ek
34. and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet 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 ope
35. ctor button in middle of drive roll carrier gt If ejector button does not re turn to normal position out install a drive roll and ejector button will pop out 804 187 A OM 228 956 Page 12 4 6 Installing PD Continuous Wire Guides E PD Continuous Wire Guides Should be used with 068 072 in 1 8 mm and smaller diameter wire for opti mal performance Should be used with PD drive rolls and cannot be used with non PD old style drive rolls E 70 series wire guides are not compatible with 75 series wire feeders Pressure Assembly Door PD Inlet Guide PD Wire Guide Hard Wire PD Wire Guide Two Pieces interlocked for Aluminum Wire Installing PD continuous wire guides with PD drive rolls cnm gt Drive rolls are identified by the initials PD and a part number on the arive roll Open pressure assembly door Lift up drive roll swing arms Remove PD inlet guide Insert wire guide gun end indi cated with arrow into block near brass power pin gun connector Install PD inlet guide Do not tighten set screw to se cure inlet guide gt Set screw may be used to se cure PD inlet guide replace ments such as wire straighten ers or conduit adapters Ref 804 192 804 188 A OM 228 956 Page 13 4 7 Installing Non PD Old Style Wire Guides Installing wire guides with non PD old style drive rolls Non PD old style wire guides and drive rolls should b
36. 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 The Adjust control is used to change various sequence parame ters and to select various se quences Refer to the section for the function in question for informa tion related to using the Adjust con trol OM 228 956 Page 23 5 9 Process Set Up Push Button 1 Process Set Up Push Button 2 Process Set Up LED Process 3 Wire Type 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 iluminate the button LED and Process LED above the button Both d
37. d 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 228 956 Page 35 gt 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 nee 212 781 WRAPPER feeder 1 Ee Sp 211 164 PANEL pc card switch overlay including 1 e SE 210 655 NAMEPLATE overlay 1 it bats PES insat 227 879 CIRCUIT CARD ASSY switches 1 5 Debate PET re 204 049 CIRCUIT CARD ASSY display micro w program 1 E TE NE OE GAN 212 808 BAFFLE pe MOUNTING 2 mro GS Ae anne ECC Enc wor a Sew eo Se We det 1 7 PC6 209681 CIRCUIT CARD ASSY motor control 1 TE usa p EE TT 211 0037 le Be En e te EEN 1 Ns 010 494 BUSHING snap in nyl 1 375 id x 1 750 mtg hole 1 SU 057 357 BUSHING snap in nyl 937 id x 1 125 mtg hole 1 TE aes RE das 211018 CONNECTOR
38. du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 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 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 228 956 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 ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins 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 2
39. e Fig 9 1 Item 4 xk d anie Ersten e ER 220 012 SCREW 250 28x 62 button soc hd zinc 4 PER Figure 9 3 DRIVE ASSEMBLY 1 iw Ov ecard Mb Nu 12271024 MOTOR 2d dde Dr DERE AE EE SEA iita Da 1 DO OER E 1229550 ENCODER quadrature 500PPR incremental 5V shaftless 1 Recommended Spare Parts THave nearest Factory Authorized Service Agent replace encoder 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 228 956 Page 39 SO 9AUP 8A0019 N N Ad UIEIUO9 LFOOOE PU OY000 6 000 SIM uinuiunje 10 Gd 91ON 804 S0 GG6 cel 907 S0 669 S0 LIS EZZ GIS EZZ 801 612 LOL EZZ 244 Le LYO 00 860 EZZ 00S ZZZ 448 vec WLU 9 29 0 Ul OL L 06v 80 966 GEL ZO4 ESO 869 ESO LLG 22 SLS EZZ 80L 612 LOL EZZ 66 222 460 Ce geen eevee Se ul ZS0 Got 80 166 Z L LOZ 8S0 269 S0 JIS ZZ GLS EZZ 801 6LZ 00L 6ZZ 044422 OvOO0 160 22 96v ccc G 8vcc luust ul Zt0 Sr0 2250019 IN SAoo ON 9A0015 N 9AOO A epin9 SpIn apiny apiny ad 9pIn weu 13 ad 911191 uone wa leIp uui lul 19IUI snonunuoy a snonunuoy aig ES ad ag dd peambei p pelinbe uoee silo elf1S PIO peinbe apinB 3 SIIO4 p JO UA L peinbe apin6 3 s
40. e Frequently inspect input power cord for damage or bare wiring 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
41. e adjoining symbols gt Means Note not safety related 1 2 Arc Welding Hazards Thesymbols 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 da
42. e used with 5 64 in 2 0 mm and larger diameter wire Pressure Assembly Door PD Inlet Guide Intermediate Guide Set Screw Guide Holder Exit Guide Open pressure assembly door O OI OO Lift up drive roll swing arms Install PD inlet guide gt Do not tighten set screw to se cure inlet guide gt Set screw may be used to se cure PD inlet guide replace ments such as wire straighten ers or conduit adapters Remove screw securing intermedi ate guide holder Guide holder is located between the lower front and rear drive roll carriers Rotate guide holder 180 degrees and reinstall Install intermediate guide into guide holder and tighten set screw Loosen set screw insert exit guide into block near brass power pin gun connection and secure with set Screw gt When using smaller diameter inlet guide 219108 with non PD old style drive rolls a 1 4 in 6 mm gap will be present between the guide and drive Tools Needed roll 1 16 1 8 5 32 in Ref 804 192 B 804 188 A OM 228 956 Page 14 4 8 Installing Welding Gun s Power Clamp Knob gt f Gun Locking Tab Power Pin Groove 4 Gun Connection End Installing gun with Accu Mate connection CO N Loosen power clamp knob to allow power pin of gun to clear the gun locking tab When installing gun the liner should extend into the PD continu ous guide or exit guide if used as far as possible without interf
43. ed 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 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
44. enses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI 749 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 a 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
45. ent which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE 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
46. ering with the guide Align the groove in the power pin of the gun with the gun locking tab Secure gun by tightening power clamp knob Installing gun without Accu Mate connection When using a gun without the groove in the power pin loosen power clamp knob and rotate gun locking tab 180 degrees This pre vents the locking tab from extend ing into the power pin gun connec tion When installing gun the liner should extend into the PD continu ous guide or exit guide if used as far as possible without interfering with the guide Secure gun by tightening power clamp knob Installing gun with Installing gun without Accu Mate connection Accu Mate connection 804 189 A OM 228 956 Page 15 4 9 3 Pressure assembly Drive Rolls door not shown No Wire Slip NONCONDUCTIVE SURFACE 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever Indicates Pressure Settings Pressure drive settings range from 1 to 8 with 8 being the maximum setting For aluminum soft wire set pressure drive setting at 4 or below Be sure that gun has proper size liner for the welding wire size OM 228 956 Page 16 Back Of Gun Install wire spool Adjust tension nut so wire is taut when wire feed stops NONCONDUCTIVE SURFACE When installing gun the liner should extend into the PD continuous guide or exit guide if used as far as possible without interfering with the guide Install gu
47. es x Cracked Parts Months ai Nj 14 Pin Cord Gas Hose And Fittings Gun Cable Every 6 Months Inside Of Unit Drive Rolls OM 228 956 Page 28 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 SENS TACH Indicates a voltage sense error Indicates a gas Indicates a coolant flow error flow error Indicates a tachometer error ERR SENS e The voltage sense error indicates no voltage sensing feedback signal Check connections at feeder and welding power source Press Jog Purge button to clear 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 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 Indicates a motor error FTP Indicates a file transfer point error is Indicates a wire feed speed error Indicates a ground current error ERR STRT e The start error occurs if the user
48. et Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 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 c bles 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
49. f 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 w Hi 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 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 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
50. ge 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 General Terms Crater Postflow Feeder Set Up Auto Thread 5 2 Power Switch 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 4 Power Switch 804 587 A OM 228 956 Page 19 5 3 Front Panel Controls Section See Section Program 9 4 Section O Process 9 wire Type O Trigger Control Gas Type 9 Trigger Hold a Feeder Set Up Section Section Section 5 9 5 8 5 7 OM 228 956 Page 20 5 4 Program Push Button 5 5 Upper Display n E Program T dn he 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 illuminate LED To change the program number rotate Adjust knob to select one o
51. has the trigger held for more than two minutes without striking an arc or if the user holds the trigger past the postflow phase in a timed weld This error also occurs if the trigger is held when the feeder is powered up The error may be cleared by releasing the trigger and pressing the Jog Purge button 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 Indicates an arc stop error Indicates an arc start error Indicates a primary power error Indicates a wire stuck error ERR FTP e The file transfer error occurs if data does not transfer to the feeder correctly Press Jog Purge button to clear error and transfer data to feeder again ERR GND e The ground current error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Press Jog Purge button to clear error ERR STUK e The stuck error occurs if
52. he power up sequence is completed approximately 20 seconds RsT_ Pr ram Ki Sequence Trigger Control Trigger Hold Volts 9 Time Arc Adjust Ei WFS Amps ArcCtl Sequence Trigger Control 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 Argon 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 OM 228 956 Page 26 Trigger Control Trigger Hold Feeder Set 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 System configuration data will be lost during the Reset operation CYCL E O Process O Wire Type Gas Type a Cycl Pwr message appears on the display
53. il est recommand de suivre les proc dures pr c dentes SECTION 3 INTRODUCTION 3 1 Specifications Type of Input Welding Power f Wire Diameter Welding Circuit Overall Power Source Type Wire Feed Speed Range Range Rating Dimensions Weight 40 Volts DC Axcess Series Standard 40 To 1400 ipm 1 0 045 To 062 in 100 Volts Length 27 in 686 70 5 Ib 10 Amperes To 35 6 mpm 1 1 To 1 6 mm 750 Amperes mm 32 0 kg 100 Duty th 191 9 Max Spool Cycle ee 2 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 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 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 e 4 VOLTS Locate unit near correct input AMPERES kW ES power supply PHASE SD Line Disconnect Device loc_2 3 96 Ref 804 585 A OM 228 956 Page 9 4 2 Connection Diagram OM 228 956 Page 10 Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative Weld Cable Workpiece Voltage Sensing Lead Optional
54. isplays 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 lower 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
55. lformations cong nitales et dans certains cas des cancers Code de sant et de s curit de 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 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
56. losion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille 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 qui
57. n Lay gun cable out straight Cut off end of wire Push wire through guide up to drive rolls continue to hold wire Press Jog button to feed wire out gun To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive i H Ch lt iit Mr Installing Welding Wire And Adjusting Pressure Drive Setting Thread wire Le Ref 804 190 A Tools Needed C P YT 15 16 in surface and press gun trigger to feed wire against surface Adjust pressure drive lever so wire does not slip Do not overtighten If contact tip is completely blocked wire should slip at the feeder see pressure adjustment above Cut wire off 4 10 Feeder Display At Power Up Lu Program NEN Volts Time Arc Adjust e NEN O Amps Arc Ctl 2 Process O Sequence O Wire Type O Trigger Control O Gas Type O Trigger Hold e Process Set Up j Feeder Set Up Power Source Upper Display Lower Display Voltage Range 300 450 675 4 11 Dual Schedule Switch Options 1 DSS 9M 1 1 Upper Display 2 Lower Display 1 Maint 2P Maintained Contact 2 Pole Switch DSS 9M Part 041 793 OM 228 956 Page 17 SECTION 5 OPERATION 5 1 Operational Terms The following 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 Sched
58. nger of falling e Use AC output ONLY if required for the welding 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
59. nings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use 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 228 956 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator H
60. nt des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le 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 l o 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 positi
61. oa y 10 3 1 9zIS SIM SIIOH SAL DIBDUB1S BAG 9IA1S PIO 10 SepinD pue dd 9JIAA pJeH 103 ad unuluin v 10 ad S3pIN5 pue SIIOd SAG SJ IS PIO dd UON pue AM UOISIO9 d Gd L 6 eldel OM 228 956 Page 40 Notes Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way OG 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 component
62. on coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou 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 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 d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d 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
63. pement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement 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 g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage AN 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des ma
64. 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 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 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 volta
65. s LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur 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 Vouie 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 exp
66. s that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted 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 HE Units Grids
67. sent s ci dessous sont utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions en 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 PA de dans la Section 2 5 Lire et amp Ne pas enrouler les c bles autour du corps id DUM i e Sila pi ce soud e doit tre mise la terre le faire directement avec un Seul un personnel qualifi est autoris installer faire fonction c ble distinct nor Shireen etreparereel appareil e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre 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 ma
68. substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusement avec des protections homologu es e Ne pas souder dans un endroit o 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
69. t riel en bon tat R parer ou remplacer sur le entrainer la mort champ les pi ces 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 p sous tension lorsque le courant est d livr la M ER 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 lsoler 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 utilisa
70. tes 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 selects either WFS or Arc Ctl 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 _ 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 welding by using the Adjust knob To return to actual values on the display exit the Arc Ctl display The lower display push button has additional functions when entering the sequence and trigger control functions see Section 5 7 5 7 Feeder Set Up Push Button 1 2 Sequence O Trigger Control old M ad Trigger H A 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
71. ule TPS Trigger Program Schedule Program Process MIG Pulse Accu pulse RMD optional Wire Type Gas Type Process Set Up Program Load Volts Time Arc Length WFS Amps Arc Control Inductance Adjust Sequence Preflow Start OM 228 956 Page 18 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 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 preselect
72. un trigger connection See gun Owner s Manual erratically during welding Check gun trigger See gun Owner s Manual Readjust hub tension and drive roll pressure see Section 4 9 Change to correct size drive roll see Table 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 228 956 Page 31 SECTION 8 ELECTRICAL DIAGRAM WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit CAN Zi SHELO CAN 1 424 COMMON PR 1 PER ie EEN e N N s Q PURGE 1 13 12 TT 124 55 5 5 5 I J12 11 gt S2 lt J13 4 724 2 13 11 dinis J10 2 gt i 424 COMMON 4 MOTOR CONTROL 410 57 pU PB 1 MICROPROCESSOR J10 1 gt J10 4 gt sad J1 PLG40 SHULD T J2 PLG42 J10 3 Re4 1 gt pel RC1 DD J15 1 J10 PLC43 24 TRIGGER
73. way from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 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 f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly

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