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Miller Electric 652 Welder User Manual

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1. eles bee ER 10 4 1 Specifications x EAT AE QOIS Y SERO S ERROR ETE NO ia 10 4 2 Duty Cycle And Overheating rete Y UE E EPERSGRMIOCET REY REG ES 11 4 3 Vol Ampere CUrves iss re doe eg rhy eem ORO WR Me Rer RICH 11 4 4 Selecting A LocatiOrii es CURE M E EU 12 4 5 Dimernsions And Weights cerne eee te ele ea on RR SOR EUER 13 4 6 TIPPING s estere eo Medd EM MUNERE YS ERDEE ot Oe Ce tbe 14 4 7 115 Receptacle And Supplementary Protectors 14 4 8 Weld Output Terminals esee ek ne ree Rh aee Ret Re med e RES 14 4 9 Selecting Cable Sizes isa annee De en yb eR e Gnp RH EE 15 4 10 Connecting Weld Output Cables 15 4 11 Mig GMAW Cable Connections 16 4 12 Mig GMAW And Flux Cored FCAW Cable Connections 17 4 13 TIG Cable Connections 18 4 14 Remote 14 Receptacle RC8 Information 18 4 15 Connecting Remote Control 19 4 16 Electrical Service 19 4517 Pla
2. and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding iy leony lou 7 10 60 8 X DNE Ded Dus cycle 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 700 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes 5 0007 4 10 Connecting Weld Output Cables Fer Do not place anything between weid cable terminal Tools Needed 3 3 4 in 19 mm 803 778 B Correct Installation Incorrect Installation A Turn off power before connecting to
3. 278 163 769 2007 08 i er Processes on as Multiprocess Welding Description EJ Arc Welding Power Source Dimension 652 and 812 OWNER S MANUAL File Multi Process Ca Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years 90 00
4. 12 RCS H Y R2 A im as ARG FORGE gm CONTROL 2 TE t RECT TPZ TRANS 107 l i 76 TRANS rh 5 C13 C14 e rH rH RCS D E H POSITIVE HIGH INDUCTANCE POSITIVE LOW INDUCTANCE NEGATIVE 218 514 B OM 278 Page 27 SECTION 8 PARTS LIST NOTE A complete Parts List is available on line at www MillerWelds com 8 1 Recommended Spare Parts Dia Part Mkgs No Description Quantity Recommended Spare Parts EE Fi 156 065 FUSE 5A 600V time delay 1 http www millerwelds com service replacementparts html Choose Genuine Select to review spare parts requirements such as filters spark plugs and fuses Choose Service Parts to download complete parts listing AR Hie Finding the right parts and Download Owner s consumables has never Manuals for complete been easier parts listing Notes OM 278 Page 28 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 wa
5. 4 1 6 EMF Informatiori x re ette mete e Pare nuo ee eae 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 2 1 Symboles utilis s db e eR Ke qu 1 2 2 Dangers relatifs au soudage l arc 1 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 3 2 4 Proposition californienne 65 Avertissements 4 2 5 Principales normes de s curit cius d E ae RAW EET 5 256 Information eda aa denis eee ney ye ode tet etti bb Lares 5 SECTION 3 DEFINITIONS iri Cee dee eee 7 3 1 General Precautionary 7 3 2 Input Connection Label Eee ER S ee QUE QUA AIRE 8 3 3 Electric Shock Airflow Label 8 3 4 Nameplate Safety Symbols 2 8 3 5 Manufacturers Rating Label For Products 9 3 6 WEEE Label For Products Sold Within The EU 9 3 7 Symbols And Definitions 10 SECTION 4 1
6. 278 16 A complete Parts List is available at www MillerWelds com 4 12 Mig GMAW And Flux Cored FCAW Cable Connections GMAW FCAW HIGH LOW INDUCTANCE Gasless FCAW PREN o Turn power before making connections E For better performance for most GMAW gas shielded FCAW DCEP applications it is recommended that weld output connections be made to the Low Inductance weld output terminal Make connections as shown jo E Regulator gt Gas Flowmeter Wire Feeder p Sy NS FCAW Gasless Pan LOW INDUCTANCE Gasless FCAW A Turn Off power before making connections E For better performance for most Gasless Flux Cored FCAW DCEN applications it is recommended that weld output connections be made to the Low Inductance weld output ter minal Make connections as shown Rear Of Wire Feeder J OM 278 Page 17 A complete Parts List is available at www MillerWelds com 4 13 TIG GTAW Cable Connections
7. SMAW Hot Start On Mode Hot Start is energized for Stick SMAW When Hot Start is energized higher short circuit am perage aids in arc starting NOTE use the Positive High Inductance weld output terminal see Section 4 9 SMAW Hot Start Off Mode For use with TIG GTAW scratch start only or sub merged arc SAW applications NOTE for GTAW use the Positive 4 High Induc tance weld output terminal see Section 4 9 3 Amperage Voltage Adjustment Control When Process Selector switch is in the SMAW GTAW position turn control clock wise to increase amperage Read amperage from outer scale of control When Process Selector switch is in the GMAW position turn control clockwise to increase voltage Volt meter value changes as control knob is turned Control can be adjusted while welding 4 Digital Meters With Process Selector switch in the SMAW GTAW position digital meters will read 0 zero with contactor off Digital meters will display actual output voltage and amperage with contactor on With Process Selector switch in the GMAW position voltmeter displays preset voltage with contactor off Voltmeter and ammeter Ref 184 936 display actual output voltage and amperage with contactor on 5 Power Switch With Indicator Light 6 High Temperature Shutdown Light 7 Remote Amperage Voltage Control Switch For front panel control place switch in Panel position For remote cont
8. l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand est en contact avec la pi ce la terre ou une lectrode provenant d une autre ma
9. Gas Flowmeter Regulator iui Turn power before making connections 22 Optional HF Unit For better performance for most GTAW applications it is recommended that electrode negative DCEN weld output connections be made to the high Inductance weld output ter minal Make connections as shown iN 4 14 Remote 14 Receptacle RC8 Information Socket Information OUTPUT A 24 volts ac Protected by supplementary protector CB2 24 CONTACTOR B Contact closure to A completes 24 volts ac contactor control circuit C Command reference 0 to 10 volts dc CC 10 volts dc CV REMOTE OUTPUT CONTROL D Remote control circuit common E 0 to 10 volts dc input command signal from remote control F tf AMPERAGE Current feedback 1 volt per 100 amperes VOLTAGE H Voltage feedback 1 volt per 10 arc volts OUTPUT 115 volts 15 amperes 60 Hz ac Protected by supplementary protector 1 G CONTACTOR J Contact closure to completes 115 volts ac contactor control circuit GND K Chassis common G Circuit common for 24 and 115 volts ac circuits REMOTE POWER ON OFF n To remote On Off switch Voltage sensing signal from Negative weld output terminal REMOTE VOLTAGE SENSING mas Voltage sensing signal from Positive weld output terminal Not Used OM 278 Page 18 A complet
10. 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 Miller
11. NEC Table 400 5 A for flexible cord and cable requirements OM 278 Page 19 A complete Parts List is available at www MillerWelds com 4 17 Placing Jumper Links er A Disconnect and lockout tag out input power before installing or moving jumper links gt Check input voltage available at site 1 Jumper Link Label Check label only one is on unit 2 Jumper Links Move jumper links to match input voltage Close and secure access door or go on to Section 4 18 230 VOLTS 460 VOLTS 575 VOLTS FRA FRA Ref S 174 973 220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS FAMA MAFA MAR PR 0 offooo loooffflo 1 fa FACTORY OPTION Ret S 174 975 380 VOLTS 520 VOLTS oo 177 N59 A 2 us Tools Needed 2 3 8 in Do not overtighten jumper link nuts 3 8 800 103 278 20 A complete Parts List
12. Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 OM 278 Page 8 A complete Parts List is available at www MillerWelds com 3 5 Manufacturer s Rating Label For CE Products For label location see Section 4 4 i 50A 12V 815A 34V X 60 100 L 815A 650A 5 u 70V 34V 34V 50A 22V 815A 44V X 60 100 L 815A 650A S AFTN 4N 44 50A 16 5V 650A 44V a X 10096 650 U 40v _2 6 U 44 Ui limax D gt 380V 95A 73 8 400V 90 69 7A 3 50H2 440V 83A 64 3A IP21M 17 50Hz 115V 15A X 100 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 230837 3 6 WEEE Label For Products Sold Within The EU Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information OM 278 Page 9 A complete Parts List
13. but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co
14. 1 Weld Output Terminal output terminal and Secure with nut so that weld output terminals 2 Supplied Weld Output Terminal Nut 2 a is 5 Do not place anything between we Failure to properly connect weld terminal cables may cause excessive heat sure that the surfaces of the weld cable and start a fire or damage your ma Remove supplied nut from weld output ter terminal and copper bar are clean chine minal Slide weld cable terminal onto weld OM 278 Page 15 A complete Parts List is available at www MillerWelds com 4 11 Mig GMAW Cable Connections A f Gas Flowmeter gt Regulator NN HIGH LOW INDUCTANCE INDUCTANCE Turn Off power before making connections Polarity For Electrode Positive DCEP connect weld cables as shown For Electrode Negative DCEN typical for 9 Gasless Flux Cored Welding reverse cable connections at welding power source NI UU alee For better performance for most GMAW and DCEN applications it is recommended that weld output connec tions be made to the Low Inductance weld output terminal Rear Of Wire Feeder HI O
15. 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 278 Page 7 A complete Parts List is available at www MillerWelds com 3 2 Input Connection Label 1 96 1 2 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection points and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 1 8 179 563 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring and exposed weld terminals can kill Close door before turning on unit 1 96 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill
16. L REMO OUTPUT CONTR L AN ADJUST POWER 6 5 Ref 184 939 1 Arc Force Dig Control Control increases SMAW short circuit amperage which allows the operator to use a very short arc length without sticking the electrode Set control at 0 for normal welding amperage and GTAW applications Turn clockwise to increase short circuit amperage 2 Process Selector Switch e GMAW Mode For use with flux Cored FCAW or submerged arc SAW applica tions SMAW Hot Start On Mode Hot Start is energized for Stick SMAW When Hot Start is energized higher short circuit am perage aids in arc starting NOTE use the Positive High Inductance weld output terminal see Section 4 9 SMAW Hot Start Off Mode For use with TIG GTAW scratch start only or sub merged arc SAW applications NOTE for GTAW use the Positive 4 High Induc tance weld output terminal see Section 4 9 3 Amperage Voltage Adjustment Control When Process Selector switch is in the SMAW GTAW position turn control clock wise to increase amperage Read amperage from outer scale of control When Process Selector switch is in the GMAW position turn control clockwise to increase voltage Volt meter value changes as control knob is turned Control can be adjusted while welding 4 Digital Meters With Process Selector switch in the SMAW GTAW position digital meters will read 0 zero with contactor off Digital meters w
17. SCR m SR SGR s me LOW 27 LZ OPTION 23 d SR1 L 20 2245 24 4 n CZ M t M HR 15 MA AB Q eu es DRE T SCR SCR SCR 4 5 6 2 9 4 0 27 s 2 IR KY TER RC6 AAAA RAA A A 1 r PLG oot N am gt a RO4 1 DK 9 1 m lt nel tens tepl PY 2 gt lt lt Re10 4 1 oco 50 eres Gere geese RC4 4 2572 lt lt 10 5 g ANP VOLT 87 Rc4 7 gt gt lt lt 11 5 METER m ele CONTROL BGARD RO4 5 55 57 lt lt ROI 1 2 amp 1 RG1 PLG1 ROS PLES 4A RC10 PLG1D lt lt lt lt 3 17 RG3 PLG3 ROG PLGIE b andl RG4 8 gt gt lt lt 11 8 RC11 PLA 1 6 RC4 PLG4 1 OPTION RC4 5 gt lt RC11 9 lt EM RC4 8 gt gt 5 lt lt lt 1 6 jo op per I dpi c qe X lt moz 2 824 c 1 lt h Den 455 4454 ww PE Bie Log L 5 FEF Eee ee RN EE p 55 BBB Y 57 E 2 74 tm Yer fu rer es 14 a CR2 CR2 53 i ON 43 79 SMAW STANT OUTPUT or ANP VOLT ON CNAB t PAN 8 cw 816 CR PLG7 PLG7 24 2 ay RG7 2
18. for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available
19. 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 T 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 nn nn e d F FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N 3 e Puton grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards 22 e MOVING PARTS can cause injury e Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 53 STATIC ESD can damage boards lt MOVING PARTS cause injury Have only qualified persons remove doors panels covers guards for maintenance as necessary e Reinstall doors panels covers or guards when mainten
20. is available at www MillerWelds com 3 7 Symbols And Definitions NOTE gt Some symbols are found only on CE products On Off Percent Amden Amperage Voltage L Gas Tungsten Arc 7 Shielded Metal Arc peres Control Panel DE Welding GTAW oe Welding SMAW E Temperature olo Wire Feeder DN Arc Force DIG G P e e Output Circuit Breaker Remote V Volts Positive High In Positive Low In ductance Weld ductance Weld lt Input Wee Output Terminal w M m Output Terminal p Direct Current Rated No Load Q Voltage Average Primary Voltage 0 Conventional Load i Voltage Line Connection Three Phase Rated Welding Bx Primary Current Duty Cycle Transformer 1 2 Pi Rectifier Degree Of Three Phase KVA 7 2 Protection 3 Ny 1 Suitable For Areas Protective Earth Of Increased Ground Shock Hazard 4 1 Specifications Amperes Input at Rated Load Output Rated Amperage Max 50 or 60 Hz Three Phase 9 Output Range DC 230 380 400 440 460 520 575 V V V V V KVA KW 50 81 71 70 VDC 650 A 44 In CC Mode CC Mode 126 77 73 66 63 54 50 4 50 34 8 650 21 Volts DC 3 8 1 9 1 8 1 6 1 9 1 1 1 4 1 52 0 76 Amp 100 Duty 40 66 VDC Cycle 10 65 V In In CV Mode CV Mode While idling Indicates sp
21. the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A Le The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill n 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if mo
22. 0 900 1000 DC Amperes 168 916 168 917 278 11 A complete Parts List is available at www MillerWelds com 4 4 Selecting A Location ac i Movement a OR Location And Airflow 18 460 mm 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Non CE Models Only Use rating label to determine input power needs Label located under front access door 4 Rating Label CE Models Only Use rating label to determine input power needs Label located on rear access door see Section 3 5 5 Line Disconnect Device Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 OM 278 Page 12 4 5 Dimensions Weights A complete Parts List is available at www MillerWelds com 4 Holes L F 34 D ESR i Front 800 453 A 801 530 Dimensions 30 in 762 mm Including lift eye 23 in 684 mm 38 in 965 mm Including strain relief 35 in 889 mm 1 1 4 32 mm 21 1 8 in 537 mm 1 1 8 in 29 mm 7 16 in 11 mm Dia Weight 545 Ib 247 kg OM 278 Page 13 A comple
23. 012000 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s 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 the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage sii ere Ph er ten obere Er ODE NR E 1 1 2 Arc Welding Hazards MEA Same REG WERE eds 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 08 4 1 5 Principal Safety Standards
24. 5 Years Parts 3 Years Labor Original main power rectifiers 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders 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 Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic
25. Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit
26. GA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 278 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause canc
27. a is safe before doing any welding Remove all flammables within 35 ft 10 7 of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 278 Page 2 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspe
28. al 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 a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard 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 FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running
29. ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle 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 provo quant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans 1910 252 a 2 iv et 51B pour les travaux chaud et a
30. ance is finished and before reconnecting input power e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any s
31. anis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 278 Page 2 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours
32. at and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion 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 are
33. ating level To resume operation release gun trigger turn Off unit and remove contact tip from workpiece Check contact tip and replace if damaged Turn On unit to continue operation OM 278 Page 24 6 4 Troubleshooting A complete Parts List is available at www MillerWelds com Trouble Remedy No weld output unit completely inoperative pilot light PL1 off Place line disconnect device in On position see Section 4 18 Check for open line fuse s and replace if open see Section 4 18 Check for proper input power connections see Section 4 18 Check for proper jumper link position see Section 4 17 Check fuse F1 and replace if necessary see Section 6 2 No weld output power switch pilot light on Unit overheated Allow unit to cool with fan On see Section 4 2 If using remote control place Output Contactor switch in Remote 14 position and connect remote control see Sections 4 14 and 4 15 If remote is not being used place switch in On position see Section 5 1 Check repair or replace remote control No weld output power switch pilot light on fan off Check for proper input power connections see Section 4 18 Check for open line fuse s and replace if open or reset circuit breaker see Section 4 18 Turn power switch off then back on If no output condition remains have Factory Authorized Service agent check SCR s Limit
34. chine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage 278 Page 1 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 indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter
35. cing Jumper LINKS o rara iure erac es ete 20 4 18 Connecting Input 21 5 OPERATION a 22 5 1 Controls Non CE 22 5 2 Controls CE Models ee pene ye ener Ee Cee aa 23 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 24 6 1 Routine Maintenance RE RENE n ie amie dette 24 6 27 O A a EAEE AE E A T ANN DOS QUU Peste ad ER TER 24 6 3 Short Circuit Shutdown 24 6 45 STroubleshootlhtg st ses ne t pad nt hehehe dadas ds Gone ies xh Eu nh d our 25 SECTION 7 ELECTRICAL DIAGRAM 26 SECTIONS PARTSLIST 2 l eu ungue RR te 28 8 1 Recommended Spare Parts 28 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products N OTE This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Ital
36. ct area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing 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 c
37. d be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single w
38. des gants de soudage et des v tements pais pour viter les br lures D LES FUMEES ET LES GAZ peuvent tre dangereux I Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galv
39. e Parts List is available at www MillerWelds com 4 15 Connecting Remote Control Per Turn off power before necting a remote control 1 Remote 14 Receptacle RC8 Connect remote control to 227 OR oR Ref 800 166 D 4 16 Electrical Service Guide 60 Hz Models 50 Hz Models Input Voltage 230 460 575 380 400 440 520 Input Amperes At Rated Output 126 63 50 4 77 73 66 54 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 150 70 60 90 90 80 60 Normal Operating 3 200 90 80 125 110 100 80 Min Input Conductor Size In AWG 4 1 6 6 4 4 4 6 Max Recommended Input Conductor Length In Feet Me 208 328 513 335 371 449 419 ters 64 100 156 102 113 137 128 Min Grounding Conductor Size In AWG 4 6 8 8 6 6 8 8 Reference 2005 National Electrical Code NEC 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class 5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase
40. e gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 278 Page 5 278 6 A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 General Precautionary Label 6 176 254B Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection
41. ecification differences for CE models Open circuit voltage is 26 volts dc if unit is equipped with optional low open circuit voltage OM 278 Page 10 4 2 Duty Cycle And Overheating A complete Parts List is available at www MillerWelds com Minutes RATED OUTPUT Duty Cycle is percentage of 10 min 1000 MODEL utes that unit can weld at rated load without overheating o 200 If unit overheats thermostat s opens output stops and cooling 650 fan runs Wait fifteen minutes for 5 unit to cool Reduce amperage lt duty cycle before welding d NOTICE Exceeding duty cycle 400 can damage unit and void warranty 300 40 50 60 70 80 90 100 DUTY CYCLE 100 Duty Cycle Continuous Welding Overheating 0 AN NS OR Reduce Duty Cycle 168 918 4 3 Volt Ampere Curves DC Volts A CC Mode 80 SMAW GTAW 70 60 50 40 SMAW 30 ARC FORCE 20 SMAW ARC FORCE 10 o 0 100 200 300 400 500 600 700 800 900 1000 Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown High inductance connection B CV Mode 7 0 GMAW FCAW 60 5 4 MED 3 20 10 MIN 0 0 100 200 300 400 500 600 700 80
42. ed weld output and low open circuit voltage Check position of Remote Amperage Voltage Control switch see Section 5 1 Check for open line fuse s and replace if open see Section 4 18 Check for proper input power connections see Section 4 18 Check for proper jumper link position see Section 4 17 Clean and tighten all weld output connections Unit provides only maximum or minimum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1 Check position of Remote Amperage Voltage Control switch see Section 5 1 Not able to obtain minimum output in CC mode Use high inductance weld output terminal when in CC mode to obtain minimum output see Section 4 9 Erratic or improper weld output Use proper size and type of weld cable see Section 4 9 Clean and tighten all weld connections Check wire feeder installation according to Owner s Manual Check position of Process selector switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 and hall device HD1 No 115 volts ac output at duplex recep tacle or Remote 14 receptacle Reset supplementary protector CB1 see Section 4 7 No 24 volts ac output at Remote 14 re ceptacle Reset supplementary protector CB2 see Section 4 7 Fan not operating Note fan only runs when cooling is necessary Check for and remove anything blocking fa
43. eld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 278 Page 1 FUMES AND GASES be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The he
44. ensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 278 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 7491 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders C
45. er birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the d
46. es and connect to grounding terminal 6 Welding Power Source Line Terminals 7 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line termi 5 GND PE Earth Ground nals Close and secure access door on welding power source Disconnect Device Input Power Connec tions 8 Disconnect Device switch shown in OFF position 9 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first Tools Needed 10 Disconnect Device Line Terminals j Connect input conductors L1 U L2 V And 3 8 in L3 W to disconnect device line terminals 38 in 11 Over Current Protection Select type and size of over current protec p tion using Section 4 16 fused disconnect switch shown Close and secure door on line disconnect device Remove lockout tagout device and place switch in the On position 800 103 C Ref 801 116 A OM 278 Page 21 A complete Parts List is available at www MillerWelds com SECTION 5 OPERATION 5 1 Controls Non CE Models DR Ako 2 a ZUM Bea 4 2 V vours amps SMAW GTAW gt 0 HOT START OFF CR FORGE AN Or o lt Shutdown ON
47. es de s curit gt un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil gt Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la Sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger n Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l on risque de tomber e Se servir d une source lectrique cou
48. evice manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION fre_som_2007 04 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les norm
49. ger le visage et les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s AS lt N e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent 9 provoquer des blessures gt 5 pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 278 Page 3 LES FILS SOUDAGE peuvent provoquer des blessures Ne pas appuyer sur la gachette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures gt e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les po
50. ic URINARY SENSE OPTION 230N 2 TI 1 H6 6 L LE FACTORY OPTION 220V 5 3 400V Ha B 4 H3 RD i 440N 4 H4 380v 2 3 S P a TD FAN po E RS CIRCUIT 1 HE B TE W 6 30V E m 5 B m M 9 4 32V 3 re AK 47 2 02 Ls amp fi ks PRO t 0 lt lt 2 xw 9 BALA 43 gt 1 d 2 Lb 4 BEN av lt gt W CB 184 RED AU 43 OG gt rh m FROM CONTACTOR 18V OR SWITCH 4 115V 2 a Aro lt aw g n Rc7 BV IV 2167 gt PLC2 BR GR SIL lt OFF b lt lt ES n WIVAK 5 y 2 5 B 2x lt GN 52 4 E AK FROM INPUT d YL BEN 2 SRA 72 wl AF 19 4 BRN 4 8 CRE IS USED GROUND CURRENT REMOTE SENSOR OPTION Ree x gt a gt gt gt Ei 9 2 Figure 7 1 Circuit Diagram OM 278 Page 26 SUPPLIED WITH LOW OPTION 25 NTT LE 29 el C778
51. ill display actual output voltage and amperage with contactor on With Process Selector switch in the GMAW position voltmeter displays preset voltage with contactor off Voltmeter and ammeter display actual output voltage and amperage with contactor on 5 Power Switch With Indicator Light 6 High Temperature Shutdown Light 7 Remote Amperage Voltage Control Switch For front panel control place switch in Panel position For remote control place switch in Remote position and connect remote de vice see Section 4 15 8 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of out put place switch in Remote position and connect remote device see Section 4 15 A Weld output studs are energized only when Output switch is in On position or while welding A Turn Off power before connecting re mote device OM 278 Page 22 5 2 Controls Models A complete Parts List is available at www MillerWelds com abia 45 1 Arc Force Dig Control Control increases SMAW short circuit amperage which allows the operator to use a very short arc length without sticking the electrode Set control at 0 for normal welding amperage and GTAW applications Turn clockwise to increase short circuit amperage 2 Process Selector Switch GMAW Mode For use with flux Cored FCAW or submerged arc SAW applica tions
52. is available at www MillerWelds com 4 18 Connecting Input Power 2 A Installation must meet all National Local Codes have only quali fied persons make this installation 3 Disconnect and lockout tagout input power before connecting input con ductors from unit Make input power connections to the welding power source first A Always connect green or green yel low conductor to supply grounding terminal first and never toa line ter minal See rating label on unit and check input volt age available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 16 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size T 40 mom Welding Power Source Input Power nections 2 Strain Relief Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor 5 Reed Switch Ground Current Sensor Optional Connect green or green yellow grounding conductor to welding power source ground ing terminal first If unit is equipped with tional ground current sensor route ground ing conductor through reed switch two tim
53. lles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Enn L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT Pr voir une p riode de refroidissement specter le cycle op ratoire nominal River e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste LES ETINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot
54. n movement Have Factory Authorized Service Agent check fan motor Wandering arc poor control of arc direction Reduce gas flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten Check for water in torch and repair torch if necessary See torch Owner s Manual Digital meter not working properly Have Factory Authorized Service Agent check control board PC1 and connections and replace if necessary OM 278 Page 25 SECTION 7 ELECTRICAL DIAGRAM amp WARNING Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed e m ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit a z E N ISN1 PTIDNAL PRIMARY mwze o e 480V 380 400 440 2 GROUND CURRENT FM cb y s
55. oor Chan VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupa
56. ou des conduites provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchau fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s Ne pas souder dans un endroit l des tincelles peuvent tomber sur des substances inflammables Se prot ger et d autres personnes de la projection d tincelles et de 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 Surveiller tout d clenchement d incendie et tenir extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS 4 1 voir les nor mes de s curit e Ne soudez pas si l air
57. que risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi q
58. rant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil tilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante 1 Indique des instructions sp cifiques e Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou
59. rol place switch in Remote position and connect remote de vice see Section 4 15 8 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of out put place switch in Remote position and connect remote device see Section 4 15 Weld output studs are energized only when Output switch is in On position or while welding A Turn Off power before connecting re mote device OM 278 Page 23 A complete Parts List is available at www MillerWelds com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Disconnect power before maintaining 3 Months Replace WARNI J Repair or OY 50 Clean and unreadable SVE replace tighten weld labels cracked weld terminals si cable 2 6 Months Blow out or vacuum inside During heavy service clean monthly 27 T 6 2 Fuse F1 gt Disconnect and lockout tag out input power before checking or changing fuse 1 Fuse F1 See Parts List For Rating Fuse 1 protects control transform er from overload If F1 opens weld 1 output and fan motor stops place F1 Close and secure access door Tools Needed f 3 8 Ref 800 101 6 3 Short Circuit Shutdown When contact tip is shorted and sticks to workpiece the unit output falls to a safe oper
60. rtes 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 Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N utiliser que les pi ces de rechange recom mand es par le constructeur 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 distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn ti
61. ssion Si une bouteille est endomma elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Lecouvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les boutei
62. te Parts List is available at www MillerWelds com 4 6 Tipping careful when placing or moving unit over uneven surfaces 4 7 115 VAC Receptacle And Supplementary Protectors Turn power before connecting to receptacle i 1 115V 15A AC Receptacle 9 Power is shared between RC9 and Remote 14 receptacle RC8 see Section 4 15 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects the 115 volts ac por tion of RC8 and RC9 from overload CB2 protects the 24 volts ac portion of RC8 and Remote Power On Off from overload Press button to reset protector Ref 800 166 D 4 8 Weld Output Terminals A Turn Off power before connecting to weld output terminals 1 Positive High Inductance Terminal 2 Positive Low Inductance Terminal 3 Negative Weld Outout Terminal See Sections 4 11 4 12 or 4 13 NT Ref 800 166 D OM 278 Page 14 A complete Parts List is available at www MillerWelds com 4 9 Selecting Cable Sizes NOTICE ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed
63. tional And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de Vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points d
64. ues dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 278 Page 4 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Fl
65. vement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes 5 Indicates special instructions PK This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards Always verify the supply ground check an
66. voir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SA o LETES peuvent provoquer des bles sures dans les yeux Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pre
67. y Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipmentto the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1
68. y S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 dos European Contact Signature Declares that the product D i m e n S i O n 81 2 conforms to the following Directives and Standards dec_stat_6 05 Directives Electromagnetic compatibility Directives 89 336 92 31 Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 April 1995 Draft revision Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1 1992 Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 A Protect yourself and others from injury read and follow these precautions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in

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