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Miller Electric 350P Welding System User Manual

1. 19 3 18 Electrical Service GUIDE i ark es a ee C D Re lg RR o ee an Cx ada CR n RU din sn diet 19 3 14 Selecting Input Voltage 200 230 460 Volt Models Only 20 3 15 Serial Number And Rating Label Location 2 21 3 16 Selecting A Location And Connecting 3 Phase Input Power 21 3 17 Selection A Location And Connecting 1 Phase Input Power 22 3 18 Threading Welding Wire For MIG Gun nnn 23 3 19 Threading Welding Wire For XR Edge XR A Gun XR A Python Or XR Aluma Pro 24 3 20 Threading Welding Wire Through XR Guns 25 SECTION 4 OPERATION sinus DADES dt Rod ancre 26 Al Ee re EE 26 42 WICIMOOS ME rrr 26 49 Jog MOUS cs cor EU EEG ete A A E 26 4 4 Weld SIGS rne kc REG ERXEERAREDE kee etai en CET CE NC a emat wie feos denses 27 4 5 MIG G n On D mand NEE SCENE REESE RR ER E Rx e eme oe em een 27 4 6 Pulse MIG Mode Voltage Adjustment a eee 27 4 7 Pulse MIG Gun On Demand 4 hs 27 ABa TME AONE A Eege be bi ee rrr T 27 4 9 Weld Parameters For MIG Mode 28 4 10 Weld Parameters For Pulse Mode
2. Installation must meet all National and Local Codes have only qualified persons make this installation A Disconnect and lockout tagout input power before connecting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal Warning This unit is either a 200 230 460 ac input voltage model or 460 575 ac input voltage model See rating label on unit and check voltage unit where it could tip available at site to be sure it matches the voltage specified on the rating label 1 Input Power Cord Strain Relief 2 Input Power Cord 3 Disconnect Device switch shown in the OFF position 4 Green Or Green Yellow Grounding Conductor 5 Disconnect Device Grounding Terminal 6 Input Conductors L1 L2 And L3 7 Disconnect Device Line Terminals Connect green or green yellow grounding GND PE Earth Ground Ref 803 543 E 803 766 A conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protection using Section 3 13 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position OM 1327 Page 21 Ls A complete Parts List is available at www MillerWelds com 3 17 Selection A Location A
3. LLI lt 5 O gt 150 200 AMPERAGE 217 443 A 3 4 Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar Tools Needed 2 3 4 in 19 mm 803 778 A Correct Installation Incorrect Installation Weld Output Terminal output terminal and secure with nut so that Supplied Weld Output Terminal Nut weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make cables may cause excessive heat EE 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 A Turn off power before connecting to weld output terminals 1 2 Failure to properly connect weld 3 Weld Cable Terminal 4 OM 1327 Page 12 Ls complete Parts List is available at www MillerWelds com 3 5 Installing Work Clamp 1 Work Cable 2 Boot Route cable through front panel opening Slide boot onto work cable 3 Negative Output Terminal Connect cable to terminal and cover connection with boot Close door Tools Needed 3 4 in 803 540 C 3 6 Installing Welding Gun Cable Holder 1 Welding Gun Cable Holder 2 Wrapper 3 Screw Locations Remove screws from side panel Place holder against side panel and align screw holes Secure holder to side panel with the
4. M MODEL ONLY lt dew da T E A A 4 N o e n R pl o oO O e e e e e e DE DE c a D D E E E VM VM YY VM V 29 30 33 34 GS1 RT2 RED BLK RL OUTPUT IGBT DIODE HS HS AA 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 Figure 7 1 Circuit Diagram For Welding Power Source OM 1327 Page 48 PC7 RELINK BOARD 230V C3 amp C4 IN PARALLEL 460V C3 amp C4 IN SERIES k JUMPER PLACEMENT 460 575 MODEL ONLY ko ES C4 IN SERIES ES A SS A IL J T1 POSITIVE i C1 21 III PM2 E1C2 O II III x III CT1 III 22 I PM1 E1C2 O C Y Il I C6 I 7 NEGATIVE O c7 BLK WHT RC 2 PUSH PULL SPOOLGUN RESTES 2 35 KK 3 B MIR RC13 1 E 36 lt C MR ca len PC3 i Zon wo A baa T 0 UT Con S 5VDC JP5 1 5 AS a JP4 PLG28 JP6 8 gt gt amp H POT COM 5VDC lt JP5 2 AGND PLG 23 45 45 SE E Ss EH DERE AERE s ENABLE DGND R is gt JP5 4 JP6 3 gt 52 MER NEN 43 G TRIG RTN x SCH 25VDC RC11 5 gt lt JP5 5 JP6 6 gt iS EE Cd x E POT CW CONNOR JP6 7 gt 39 K e sem 39 F POT WIPER RIBBON CABLE JP6 5 gt gt 40 40 J XR 13 x PC9 2 d P CENE UN mi dus 1820 L AGND a npn 42 lt 2 TRIG RTN RXD RC62 1 RCI 1 TD 9
5. 0 29 TABLE OF CONTENTS SECTION 5 PROGRAMMING ias Ca kS o Ede Coa u ee ee es 5 1 MIG Welding Mode de e geste ok eee eee EOD Rede RR a dti nea EROR UC RUE aussi 5 2 Pulse MIG Welding Mode 5 3 Timers 5 4 Arc Times Arc Starts Hot Start Aluminum Pulse Only And Crater Fill 5 5 Setting Hot Start Aluminum Pulse Only Parameters 5 6 Setting Crater Fill 5 7 Recommended Crater Fill Parameters 5 8 System Reset 5 9 Motor Calibration Function ucl cd ec dates d Ro a C Did el ende ay alee soe D S ete ac 5 10 Set Up Push Motor Torque SUP secs xus uk ha dans Re bee oae Rl uh uhuy DECORE SECTION 6 MAINTENANCE amp TROUBLESHOOTING HH hh mh nn 6 1 BoulneMalntenatlee csuu s dci ans alicia cosa s dO Goad noe ads Si i ppum hap ER REX q 6 2 Overheating 6 3 Measuring Input Capacitor Voltage a ms 6 4 Changing Drive Roll and Wire Inlet Guide 6 5 Help Displays 6 6 Troubleshooting SECTION 7 ELECTRICAL DIAGRAM giereg ENEE ENEE eee aa EE d SECTION 8 PARTS LIST WARRANTY 30 30 31 32 33 34 35 36 38 39 40 41 41 41 42 43 44 46 48 50 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2010 03 Protect yourse
6. NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder 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
7. A gt gt OM Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des 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 ques 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 Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent 1327 Page 8 des cancers des malformations cong nitales ou d autres problemes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat 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 Weldi
8. Q Miller Millermatic 350 And Millermatic 350P OM 1327 213 814AD 2010 04 Processes MIG GMAW Welding Pulsed MIG GMAW P c Flux Cored FCAW Welding FC Description PHG E3 EB Arc Welding Power Source and Wire Feeder Visit our website at www MillerWelds com OWNER S MANUAL File MIG GMAW m 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 Y E BI E 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 boleu Ie ete jue ere ex 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
9. distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE 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 inter nes 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 talli ues 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 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 e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique a courant lectrique s av re n cessaire se servir de la fonction de t l commande si l app
10. 575 200 230 460 575 Input Amperes A At Rated Output 69 61 30 24 34 30 15 12 Max Recommended Standard Fuse Rating In Amperes Time Delay Fuses 2 80 70 35 25 40 35 15 10 Normal Operating Fuses 3 100 90 40 35 50 45 20 15 Min Input Conductor Size In AWG 4 6 8 10 12 10 10 14 14 Max Recommended Input Conductor Length In Feet Meters a E a as as SS Min Grounding Conductor Size In AWG 8 8 10 12 10 10 14 14 Reference 2008 National Electrical Code NEC including article 630 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 RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements NOTICE This unit is either a 200 230 460 ac input voltage model or 460 575 ac input voltage model See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label OM 1327 Page 19 Ls A complete Parts List is available a
11. CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 TEE Se anao a i ire tole d ac do d oA eco Does arai E ener ka 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 8 2 5 Principales normes de S curit ssas side ue dox e rct wee met ele done aed D e E eal fe 9 2 6 Informations relatives aux CEM hrs 9 SECTION 3 INSTALLATION EE 11 35 li erer e 11 3 2 Duty Cycle And Overheallhg eege d Rae ates e euet ur ee ne ees 11 3 9 CMOIEATIDOLO OUO iur od Re caddie inet etie Danai M EE Sata me huata uh a Cx cea Sed 12 3 4 Connecting To Weld Output Terminals 12 3 5 Installing Work Clair ER Rat oe ee ESCORT UNSS 13 3 6 Installing Welding Gun Cable Holder 2 13 3 7 Installing Welding GUM 34 3 t x ERRARE RIDERE GET IA A AAA Eee SRE 14 3 8 Connecting Spoolmatic 15A Or 30A Gun 15 3 9 Connecting XR Edge XR A Gun XR A Python Or XR Aluma Pro 16 3 10 Setting Gun Polarity For Wire Type 4 rut 17 STI Installing GaS ee ENEE 18 3 12 Installing Wire Spool and Adjusting Hub Tension
12. de soudage les manipuler avec pr caution e Prot gerles 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 Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion 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 e 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 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
13. 0 5 GE SE 34 30 15 12 11 6 11 5 Cycle Cycle a i d PIRE NES uso 1 5 0 75 0 5 While idling Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Solid Steel Stainless Steel Aluminum 50 700 IPM H 34 in 864 mm 181 Ib 1 3 17 W 19 in 4 2k 023 045 in 030 045 in 035 047 in EE a P 0 8 1 1 mm 0 8 1 1 mm 0 9 1 2 mm Operating Temperature Range 20C to 40C Storage Temperature Range 30C to 50C 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermistors open output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 25 30 40 50 60 70 8090 100 E DUTY CYCLE WELDING AMPERES 6096 Duty Cycle At 300 Amperes 4096 Duty Cycle At 350 Amperes 6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting Overheating GC O AL S sb Reduce Duty Cycle Minutes sduty1 5 95 217 442 A OM 1327 Page 11 Ls A complete Parts List is available at www MillerWelds com 3 3 Volt Ampere Curve 1 Normal Volt Ampere Curves The volt ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown
14. and open valve slightly Gas flow blows dust and dirt from valve 3 Close valve 3 Cylinder 4 Regulator Flowmeter ge Argon Gas Or Mixed Gas Install so face is vertical 5 Regulator Flowmeter Gas T 1 Hose Connection 6 Welding Power Source Gas Hose Connection p d 2 Connect supplied gas hose N between regulator flowmeter gas EE I hose connection and fitting on e rear of welding power source 7 Flow Adjust 8 9 Typical flow rate is 20 cfh cubic feet per hour Check wire CO Gas manufacturers recommended flow rate 8 CO Adapter Customer Supplied 9 O Ring Customer Supplied Install adapter with O ring between regulator flowmeter and CO cylinder Rear Panel Tools Needed Q 1 1 8 5 8 in 803 542 C OM 1327 Page 18 EF A complete Parts List is available at www MillerWelds com 3 12 Installing Wire Spool and Adjusting Hub Tension Use compression spring with 8 in 200 mm spools When a slight force is needed to turn spool tension is set Tools Needed dE Je 15 16 in Ref 805 023 A 3 13 Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommendationsare for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 60 Hz Single Phase 60 Hz Three Phase Input Voltage V 200 230 460
15. 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 facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 1327 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloign
16. 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 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 LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d
17. hazards e Do not use welder to thaw frozen pipes OM 1327 Page 2 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 inspect 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 e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical Devices e 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
18. pulse board if necessary Help 10 Indicates a trigger error when two gun triggers are activated at the same time Release gun triggers to clear error Help 11 Indicates a tach error when tach feedback signal is not present Release and press gun trigger to reset tach signal If error continues contact a Factory Authorized Service Agent Tip Save Indicates contact tip is directly shorted to workpiece Arc shuts off in this condition and message resets when tip is not touching workpiece and gun trigger is released MM 350P When unit is turned on this display indicates that pulse option is installed and operational MM 350 When unit is turned on this display indicates that unit is either a MIG only machine or pulse option is installed but not operational Jog XXX Wire Feed Speed Indicates trigger is pressed but no arc is detected Wire feed speed goes to Jog wire feed speed after 3 seconds SC 187 212 A OM 1327 Page 45 EF complete Parts List is available at www MillerWelds com 6 6 Troubleshooting Trouble Remedy No weld output wire does not feed Be sure line disconnect switch is On see Section 3 16 or 3 17 Replace building line fuse or reset circuit breaker if open see Section 3 16 or 3 17 Secure gun trigger connections see Section 3 7 Have Factory Authorized Service Agent check Power switch Have Factory Authorized Service Agent ch
19. quired for feeding aluminum Wire Tools Needed 5 Drive Roll Securing Nut 5 64 in Turn nut one click to secure drive roll IE 7 16 in 802 520 B OM 1327 Page 43 Ls complete Parts List is available at www MillerWelds com 6 5 Help Displays ses ses HELP ELP ei d TIP e SAVE HELP ELP 8 D XY es V A V A maur s ww V A V A war 7 posje EE Displays a jog wire feed speed OM 1327 Page 44 EF A complete Parts List is available at www MillerWelds com gt All directions are in reference to the front of the unit All circuitry referred to is located inside the unit Help 0 Indicates overheating on left side of unit displays flash between OVER TEMP and HELP 0 Unit will shutdown until internal temperature drops within operational range Help 1 Turn off primary input power and check input voltage per primary voltage rating of welder and correct if necessary If HELP 1 persists this Indicates a communication error between control board PC1 and user interface board Contact nearest Factory Authorized Service Agent Help 2 Indicates overheating on right side of unit displays flash between OVER TEMP and HELP 2 Unit will shutdown until internal temperature drops within operational range Help 3 Indicates gun trigger was pulled and held during power up Release gun trigger and clear fault condition Also this display can Indicate no open circuit voltage detected w
20. 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 notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit NEZ FALLING EQUIPMENT can injure 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 e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure 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 STATIC ESD can damage PC boards 3 e Put on grounded wrist strap
21. 50 1 0 100 35 1 5 19 20 1 5 120 30 1 50 105 30 1 25 Wire speed Arc length Time pu 14 ga 16 ga 18 ga ODE 20ga 2 0 mm 1 6 mm 1 2 mm t 0 Xo 9mm 90 13 5 0 5 90 13 5 075 90 13 5 0 5 m 50 15 1 0 50 15 1 0 50 15 1 0 50 15 1 0 50 15 1 0 15 15 0 75 75 15 0 75 5 15 0 5 SCH 15 15 0 5 75 15 0 75 15 15 0 75 e 75 15 0 75 75 15 0 75 75 15 0 75 200 11 0 90 SCH Ge m 85 30 1 0 85 30 1 0 85 30 1 0 SE Se 5 30 1 0 75 30 0 75 75 30 0 75 SC 90 30 0 75 90 30 0 75 75 30 0 75 SC 75 30 1 0 50 30 0 75 50 30 075 SC 130 45 1 0 115 40 1 0 115 40 1 0 100 20 1 5 100 25 1 2 100 25 1 2 100 35 1 0 15 20 1 5 15 20 1 0 15 20 1 0 x 120 30 1 0 120 30 1 0 120 30 1 0 120 30 1 0 105 30 1 0 105 30 1 0 105 30 0 75 SC 187 212 A OM 1327 Page 37 EF complete Parts List is available at www MillerWelds com 5 8 System Reset Accessing the System Reset function will also allow access to Timer Reset 779 and Option Reset 57 functions The timer reset and option reset functions are for use by factory authorized service personnel only Do not use the timer reset or option reset functions if they appear on the displays e O PROCESS O WIRE O TIMERS i ARC CONTROL A system reset function is available that completely resets unit back to all the original factory settings To access this menu turn on welding power source then press
22. BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 em MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 5 MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place Ki e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 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 e
23. Pressure Adjustment Knob Gun Conduit Cable Lay gun cable out straight ON O Om Go N Tools Needed C P gt IMPORTANT L Hold wire tightly to keep For Aluminum Push Pull welding Thread hub tension nut loosely it from unraveling 218243 A y Pull and hold wire cut off end IMPORTANT For Aluminum Push Pull welding Pressure Indicator Scale Push wire thru guides into gun continue to hold wire Close and tighten pressure L Use pressure indicator scale to assembly and let go of wire set front drive roll pressure to 1 and rear drive roll pressure to less than 1 See Section 3 20 for threading welding wire through XR guns Ref 803 544 B 218 243 A 218 244 A S 0627 A OM 1327 Page 24 EF complete Parts List is available at www MillerWelds com 3 20 Threading Welding Wire Through XR Guns Y gt Welding wire is electrically live SD 2 gt f Eq when gun trigger is used to jog m wire For XR A Edge Gun L3 Refer to Section 3 19 for instructions on feeding wire through welding pow er Source 1 Pressure Roll Assembly Lay gun cable out straight Open top cover and open pressure roll as sembly If not already done remove gun barrel assembly Press gun trigger until about 4 in 102 mm Turn On qb one Welding Power of wire is sticking out front of gun Insert Source wire into barrel liner and tighten barrel as sembly Install correct s
24. Rotate left knob 2 to change display to TIME and rotate right knob 3 to set crater time Time range is 0 1 5 0 seconds see Section 5 7 Rotate left knob 2 to change display to VOLT MIG program or ARLL pulse program and rotate right knob 3 to set either volts range is 10 0 32 0 volts or arc length range is 0 99 see Section 5 7 Ref 213 935 A Rotate left knob 2 to change display to TDLY for time delay This setting is for spot or skip welding without crater fill if the arc time is less than the set time Time range is 0 0 5 0 seconds i e if TDLY is set for 2 0 seconds weld operation will not go into crater if gun trigger is released before 2 0 seconds To exit this menu press the SETUP 1 button OM 1327 Page 35 Ls complete Parts List is available at www MillerWelds com 5 7 Recommended Crater Fill Parameters Evi Crater Parameters Wire Sizes Diameter Suggested Suggested Wire Types Shielding Gases What Material are You Welding What Process are You Using OM 1327 Page 36 Steel Solid or hard 75 Co 25 Ar 0 035 0 9mm M AES 0045 1m Stainless Steel Stainless steel Tri Mix 0 035 0 9mm ER 308LSI 90 He 7 5 Ar H ER 30QLSI 2 5 Co Uae lela 3 Steel Metal Core 90 Ar 1096 Co 0 045 1 1mm 400 26 7 1 0 Aluminum 4043 100 Ar 0 035 0 9mm 300 22 2 0 0 047 1 2mm 190 21 5 1 15 Aluminum 5356 10096 Ar 0 035 0 9mm 0 047 1 2mm 1
25. adjusted from 0 99 All Pulse MIG programs are set with a value of 50 Adjusting the Arc Length will vary the length of the welding arc cone 0 Setting 99 Setting Low Setting High Setting If a gas is used other than what is listed on the Pulse MIG welding program chart the Arc Length can be adjusted to help custom ize your arc to the gas being used Ref 213 935 A ARC CONTROL Pulse MIG 1 2 welding mode Depress ARC CONTROL 7 button to enter Arc Control menu for sharp arc SHRP will ap pear on the left display and the correspond ing setting will appear on the right display The setting can be adjusted from 0 50 and all Pulse MIG welding programs are de signed with a setting of 25 Adjusting the Sharp Arc setting will vary the width of the welding arc cone 0 Setting 50 Setting Low Setting High Setting If a gas is used other than what is listed on the Pulse MIG welding program chart the Sharp Arc can be adjusted to help custom ize your arc to the gas being used OM 1327 Page 31 complete Parts List is available at www MillerWelds com 5 3 Timers 3 T 4 T PROCESS 5 O WIRE Tee TIMERS SETUP SETUP ARC CONTROL To enter the TIMERS 5 menu depress the SETUP 6 button 4 times or until the TIMERS light 5 is illuminated Items that can be adjusted in this menu are Run in speed XI The speed of the wire prior to the welding arc
26. cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits 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 AY LA CHUTE DE L QUIPEMENT peut provoquer des blessures 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 e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e N
27. dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 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 Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Com
28. ebzz eb6L epg epg eby 8 4 9 L VIL SLYVHO QI3AM uueel 49 LYVHO ASINd uuz z L el L 9S S v9 9GEG SEO Ev0r v9 tO Ge uoBuv 9600L WINUILUN Y 6 09 OL uoBly 9606 9109 E19 N XIN HL OO 8H V 9919 ss lurels 09 OL uoDuy 9606 9918 M seg 21191210 CZ OILD DYS OS 113uo 240 synvfop Suimoyjof 21 uo Pasvq 91D 42 21uD4D0d DY NV OM 1327 Page 29 Ls complete Parts List is available at www MillerWelds com SECTION 5 PROGRAMMING 5 1 MIG Welding Mode 7 Ae 27 MIG S 3 VOLTS 4 m PROCESS 5 alae WIRE Ss TIMERS Tos 7 Fig ARC CONTROL When the MIG light 2 is illuminated the unit is in MIG Welding mode SETUP To enter MIG welding mode depress the SETUP 6 button once to go to GUN selection Rotate the right knob 9 to select the gun being used Select if for standard MIG gun or select XR A EDGE PYTH ALPR for push pull guns or 5PL for spoolgun Depress SETUP 6 a second time to illuminate the PROCESS 3 light Rotate right knob 9 until 5 is displayed for MIG only units NOT USED will be displayed OM 1327 Page 30 Depress SETUP 6 button again to illuminate the WIRE 4 light Adjust left knob 8 to select wire type adjust right knob 9 to select wire size Depress SETUP 6 button again to illuminate TIMERS 5 light For description of the T
29. material leather heavy cotton or wool and foot protection FRA WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire 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 Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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
30. on years MI 0001 of reliable service with proper maintenance And if for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in SU ba os exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service Information for your t iQ 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 7 Miller Mil_ Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad ane E e L Lu tiyu ete RA RR Re ae eee ten eee uns audi a i s aa ate ios aa 1 152 Are Welding Hazards o REDDERE EEUU uim deu a des ur ess 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 555 P ncipal Satety Standarda e cart dh Pee asus ib us Dex qi ua gue baa een qu eee ate 4 156 AAA O 4 SECTION 2
31. previously removed screws Ref 803 545 D Ref 803 539 C OM 1327 Page 13 gt complete Parts List is available at www MillerWelds com 3 7 Installing Welding Gun OM 1327 Page 14 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob Insert gun end through opening until it bottoms against drive assembly make sure gun end does not touch drive rolls Tighten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door Ref 803 541 C Ls A complete Parts List is available at www MillerWelds com 3 8 Connecting Spoolmatic amp 15A Or 30A Gun 1 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 2 Weld Cable 3 Shielding Gas Hose Route weld cable and gas hose through opening in front panel 4 Positive Weld Output Terminal Connect weld cable to weld output terminal 5 Regulator Flowmeter Route shielding gas hose through wire drive compartment out opening in rear panel and up to regulator flowmeter Connect gas hose to regulator flowmeter Tools Needed 2 3 4 5 8 in 803 568 D OM 1327 Page 15 complete Parts List is available at www MillerWelds com 3 9 Connecting XR Edge XR A Gun XR A Python Or XR Aluma Pro L XR Edge guns prior to serial no LEO79101 require an adapter cord part no 195 498 1 Gun End 2 Gun Liner 3 Wire Outlet Guide Trim excess liner from end of gun
32. provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e 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 e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e 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 e Surveiller tout d clenchement d incendie et tenir un 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 a AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter
33. s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS all e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs 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 sig
34. so no more than 3 32 in 2 4 mm of liner extends past wire outlet guide 4 Gun Securing Knob Loosen securing knob Insert gun end through opening until it bottoms against drive assembly make sure gun end does not touch drive rolls Tighten knob Be sure to change drive rolls to the proper size and type 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 803 569 C Ref 803 570 C Ref 803 463 OM 1327 Page 16 Ls complete Parts List is available at www MillerWelds com 3 10 Setting Gun Polarity For Wire Type m m 1 Polarity Changeover Information 4 EA C h a n g I n g P O a rity Always read and follow manufacture s Wire Drive O Assembly Lead NA DR OO recommended polarity Work Clamp Lead Ulo Positive Negative Terminal Terminal Shown as shipped Electrode Positive DCEP For solid steel stainless steel aluminum or flux core with gas wires GMAW Electrode Negative DCEN Reverse lead connections at terminals from that shown above for gasless flux core wires FCAW Drive assembly becomes negative II 3 4 11 16 in Ref 803 541 A OM 1327 Page 17 Ls complete Parts List is available at www MillerWelds com 3 11 Installing Gas Supply Obtain gas cylinder and chain to running gear wall or other stationary support so cylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve 1 2 Remove cap stand to side of valve
35. 0 1 0 91 GEIER GOI S 8L 091 S 81 UIUJ9 epg DOC gt S c 0 0c S c 0 0c SICH 00g 9 9 01L 0 61 GZ1 0 6L WIW0 Z ebpL Ov 0 61 0G 0 61 0Sc S 6l IECH DOG Ce OSc S 0c Sc 0 Lc 041 821 093 0 81 0S1 0 0c OLc 0 Oc LUC 49 L S 0 Lc OcS 0 Lc S0 S Lc OGSv S Le OSE S vc 00 0 c S S Lo 00c 0 81 GZc S 8l S 1 S 0c Orc S 0c uug y UE S9v S cc 099 0 c S 0 c O S 0 c 00v 0 9c 00v 0 vc Orv G cc 0cc 0 6L 0 S 61 00c S Ic 083 S LZ uu 9 D L 00S S c 008 S c Gev s ed DO IG Ce Scv 0 2c 0G 0 Gc Avdds S8v G 8C 02c 0 c Sc 0 c ululc 6 B E S S 0 vc SZv O vc S v 0 6c DG Ge 9GEG v9 9GEG GEO Eror v9 Eror GO suoiisod Bulpjam Jo sjuiol Bulpjam jo sad 19410 10J payipoui aq o paeu few sBuIyeS spjam Jo JB UOZHOH 40J sBun1 s aduasajas Ssajawiesed Ley Up 910N LYVHO SIN uoDuy 96001 09 XOL uoDuy 9506 00 G S uoDuy oC UNIISH 9606 oO SZ uo Iy S oO 96001 ser 08 aguejonpul umuluniv 08 aguejonpul 2109 EN 08 09 eouegjonpul eeis ssejureis Ov Oc eougjonpul 19918 Ov Oc eougjonpul 19918 149 1E N OM 1327 Page 28 Ls A complete Parts List is available at www MillerWelds com 4 10 Weld Parameters For Pulse Mode LYVHO ASINd wug0 uum uuzi uug uuoz uuzg uwug y wwp 9
36. 2002 2 gt lt IE rvb RC 1 MIG 2 TXD RC62 2 gt lt RCI 2 RD a 0 I I I I 5 5 GND RC62 5 gt lt RCI 5 GND Y DE DE 5 m DE c c Y V EECHER 31 32 MIG RS 485 MOTOR ei AA AAA piers ae BD T 1 LI 3 Tege RC1 PLG30 oo RC2 PLG29 amp 6 PC7 OPTICAL TACH 246 030 B OM 1327 Page 49 SECTION 8 PARTS LIST 8 1 Drive Roll And Wire Guide Kits gt Base selection of drive rolls upon the following recommended usages V Grooved rolls for hard wire U Grooved rolls for soft and soft shelled cored wires U Cogged rolls for extremely soft shelled wires usually hard surfacing types V Knurled rolls for hard shelled cored wires Drive roll types may be mixed to suit particular requirements e g V Knurled roll in combination with U Grooved Drive Roll Wire Guide PartNo Type Inlet intermediate Q G N 046780 05369 056192 056206 rem em rem 056208 ven 059 697 eem 056207 1 16 in 053 699 056 195 056 209 056 207 056 209 056 206 056 207 056 207 056 209 Ref S 0025 D gt A complete Parts List is available at www MillerWelds com OM 1327 Page 50 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 C
37. 80 18 5 1 25 Steel Solid or hard 90 Ar 10 Co 0 035 0 9mm 85 40 1 0 D SE 0 045 1 1mm 75 30 2 0 U Stainless Steel Stainless steel Ar He Co 0 035 0 9mm ER 308LSI M ER 309 S Tri Mix 0 045 1 1mm Steel Metal Core 90 Ar 10 Co 0 045 1 4mm 335 45 1 0 Aluminum 4043 100 Ar 0 035 0 9mm 100 35 2 0 S 0 047 1 2mm 75 20 1 5 Aluminum 5356 100 Ar 0 035 0 9mm 0 047 1 2mm gt complete Parts List is available at www MillerWelds com MIG SETTINGS EXAMPLE Wire speed Volts Time 90 13 5 1 0 EN DE mmm emm 3 8 1 4 3 16 1 8 9 5 min 6 4 mim 4 8 mm 3 2 mm 90 13 5 1 0 90 13 5 1 0 90 13 5 0 5 90 13 5 0 75 125 19 2 0 50 15 1 0 50 15 1 0 50 15 1 0 75 15 0 75 f5 15 0 5 75 5 0 75 75 15 0 75 75 15 1 25 75 15 1 25 5 15 1 25 79 15 0 75 390 24 5 1 0 300 23 5 1 0 250 23 1 0 300 22 2 0 190 21 5 1 15 190 21 5 1 15 200 19 5 1 25 85 40 1 0 79 30 2 0 90 30 1 0 75 30 2 0 270 45 1 0 100 35 2 0 79 20 1 5 200 12 1 25 200 12 1 25 250 19 5 1 25 250 17 1 25 180 18 5 1 25 180 18 5 1 25 180 16 1 25 85 30 1 0 5 30 2 0 90 30 1 0 T5 30 2 0 230 45 1 0 100 35 2 0 19 20 1 5 120 30 1 75 105 30 1 50 85 30 1 0 19 30 1 5 90 30 1 0 75 30 1 0 179 50 1 0 100 35 2 0 19 20 1 5 120 30 1 50 105 30 1 50 225 22 8 1 0 150 11 1 25 215 17 1 0 250 17 1 25 180 16 1 25 85 30 1 0 15 30 1 0 90 30 1 0 75 30 1 0 190
38. AL 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 WARRANT Y 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
39. IMERS refer to TIMERS menu see Section 5 3 If crater fill function menus are enabled TIMERS light will stay on to allow for adjust ment of crater parameters and timers see Section 5 6 Depress SETUP 6 button again to exit menus and enter MIG welding mode OPERATION Adjust welding Voltage with left knob 8 and Wire Feed Speed with right knob 9 Refer to MIG welding chart for proper Voltage and Wire Feed Speed setting in reference to material type material thickness wire and gas see Section 4 9 Ref 213 935 A ARC CONTROL MIG welding mode Depress ARC CONTROL 7 button to enter Arc control menu and INDU will appear on the left display and the corresponding setting will appear on the right display Adjust right knob 9 to adjust inductance setting In MIG welding mode the Arc control is an inductance control from 0 99 Refer to MIG welding chart for suggested Inductance setting for the wire and gas types being used see Section 4 9 Changing the inductance will change the fluidity of the puddle MA _ a Low Inductance High Inductance Weld Bead Weld Bead 0 setting 99 setting EF A complete Parts List is available at www MillerWelds com 5 2 Pulse MIG Welding Mode lt WIRE i TIMERS Pid LENGTH SPEED 7 EN ARC CONTROL When the PULSE MIG 1 2 is illuminated the unit is in Pulse MIG Welding mode SETUP To enter Pulse MIG we
40. 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 E 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 2010 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 Heplacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Weld
41. RES Tools Needed C REO 5 16in OM 1327 Page 42 Significant DC voltage can remain on capacitors after unit is Off Always check ca pacitors as shown to be sure they have discharged before working on unit Turn Off welding power source and disconnect input power Remove case 1 Input Capacitor C3 Terminals 2 Input Capacitor C4 Terminals 3 Voltmeter Check input capacitors as shown Measure the dc voltage across the positive and negative terminals until voltage drops to near 0 zero volts Proceed with job inside unit Reinstall case when finished 221 044 A Ref 803 550 B Ls A complete Parts List is available at www MillerWelds com 6 4 Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Intermediate Guide 4 Drive Roll Ls The drive assembly comes equipped with factory installed 035 045 combina tion drive rolls Be sure that all 4 drive rolls are installed cor rectly Combination drive rolls consist of two different sized grooves The stamped markings on the end sur face of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the carrier gear is the groove for the wire size viewed on the end surface of the drive roll Install correct drive roll for wire size and type L gt U Grooved drive rolls are re
42. ards Indicates special instructions e a d 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 e Properly install and ground this equipment according to its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e 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 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 rep
43. areil 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 talliquestelles 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 7 Indique des instructions sp cifiques 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 dans l ordre indiqu 1 un poste souder DC tension constante 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 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 d
44. ation function The software version data and motor calibration function are for use by factory authorized service personnel only Do not use the motor calibration function if it appears on the displays d N PULSE MIG VOLTS ND SETUP E AMPS SETUP O PROCESS 2 O WIRE a O TIMERS 1 Ne ARC CONTROL 3 Ref 213 935 A Arc times and number of arc starts are To turn on the Crater Fill display rotate left PEDE saved in unit memory To view this knob 3 until CATR appears in the left LZ The Crater Fill display can be turned information press both SETUP 1 and display The factory default for Crater Fill off after parameters are set in pro ARC CONTROL 2 buttons at the same o DEE A grams but remember that once crater time EE CN fill is turned on in any program it will p a 1 display Rotate the right knob 4 until ON remain on even though it does not ap s AU kah kakak appears in the display pear in the displays because Crater Rotate left knob 3 and display will change Fill display is turned olf to show number of arc starts To exit this menu press either the SETUP 1 or ARC CONTROL 2 button or press a gun trigger on any welding gun connected to the unit OM 1327 Page 33 complete Parts List is available at www MillerWelds com 5 5 Setting Hot Start Aluminum Pulse Only Parameters y L The factory default setting for Hot Start is Auto on 350P models The Auto setti
45. being struck This setting is a percentage of the Wire Feed Speed the unit is set to for welding Programming value ranges from 25 150 Preflow FRE The amount of time that the shielding gas will flow after the trigger is OM 1327 Page 32 gt depressed and before the welding arc will be allowed to be active Range of setting is from 0 5 seconds Postflow P557 The amount of time that the shielding gas will flow after the arc has been shut off Range of setting is 0 10 seconds Spot Timer 5727 The amount of time that the arc will be active before it shuts off automatically Range of setting is from 0 120 seconds Spot timer is reset upon re lease of welding gun trigger Ref 213 935 A Display 5P Allows the Wire Speed display to show actual welding amperage while arc is active and for 5 seconds after arc is shut off Setting is either AMPS or WFS for standard Wire Feed Speed Once in the TIMERS 5 menu rotate the left knob 8 to find a particular item and ro tate the right knob 9 to change setting or status Depress SETUP 6 button to get out of TIMERS 5 menu and to enter welding mode EF A complete Parts List is available at www MillerWelds com 5 4 Arc Times Arc Starts Hot Start Aluminum Pulse Only And Crater Fill m EN d Es Accessing the Arc Times Arc Starts Hot Start aluminum pulse only and Crater Fill data will also allow access to Software Version data and Motor Calibr
46. ce line terminals 11 Over Current Protection Select type and size of over current protec tion using Section 3 13 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position Ls complete Parts List is available at www MillerWelds com 3 18 Threading Welding Wire For MIG Gun Wire Spool Welding Wire Inlet Wire Guide Drive Roll Intermediate Wire Guide Outlet Wire Guide Pressure Adjustment Knob Gun Conduit Cable Lay gun cable out straight ON OOF Go N 8 Tools Needed gt Hold wire tightly to keep it from unraveling Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire L Use pressure indicator scale to set a desired drive roll pressure Pressure Indicator Scale Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire Press gun trigger until wire Feed wire to check drive roll pressure Cut off wire Close comes out of gun Reinstall Tighten knob enough to prevent slipping and latch door contact tip and nozzle 803 570 C S 0627 A OM 1327 Page 23 gt complete Parts List is available at www MillerWelds com 3 19 Threading Welding Wire For XR Edge XR A Gun XR A Python Or XR Aluma Pro Wire Spool Welding Wire Inlet Wire Guide Drive Roll Intermediate Wire Guide Outlet Wire Guide
47. ching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e 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 Stand
48. e adjusted WIRE SPEED illuminates in either Pulse MIG or MIG welding mode indicating wire speed can be adjusted AMPS illuminates indicating welding amps appears in the display instead of wire speed during welding and for 5 seconds 6 Setup Button 11 Right Display after the arc is extinguished gt The first time the welding power source is energized it starts in MIG welding mode Each time after the initial startup when the unit is turned off whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized 4 2 MIG Mode In MIG mode VOLTS is lit under left display and WIRE SPEED is lit under right display Left knob is used to adjust welding voltage within a range of 10 32 volts and right knob is used to adjust wire feed speed within a range of 25 700 IPM Refer to weld chart in front compartment for proper parameter settings according to wire type shielding gas and material type and thickness 4 3 Jog Mode If gun trigger is pressed and held for more than 3 seconds without striking an arc unit will automatically shut off weld power For MIG guns shielding gas will shut off after 1 minute and for spool guns shielding gas will continue to flow OM 1327 Page 26 Ls A complete Parts List is available at www MillerWelds com because gas valve is located inside spool gun For MIG guns wire will feed for up to 2 minutes while trigger is pressed then wire drive system i
49. e l op rateur et les normes nationales provinciales et locales e 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 c bles 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 entrainer 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 e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s a deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi
50. e pas obstruer les passages d air du poste WW LES TINCELLES PROJET ES peuvent provoquer des blessures e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuvre 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 P 4 Q S e LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits 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 antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 1327 Page 7 a GO Les PI CES MOBILES peuvent causer 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 Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PIECES MOBILES peuvent causer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill
51. eck all board connections and main control board No weld output wire feeds Thermistor RT1 or RT2 open overheating Allow fan to run the unit will be enabled when it has cooled and temperatures are within acceptable limits see Section 3 2 and 6 2 Connect work clamp to get good metal to metal contact Replace contact tip see gun Owner s Manual Have Factory Authorized Service Agent check main control board and main rectifier Low weld output Connect unit to proper input voltage or check for low line voltage see Section 3 16 or 3 17 Have Factory Authorized Service Agent check main control board and user interface board Low high or erratic wire speed Readjust front panel settings see Section 4 1 Change to correct size drive rolls see Section 6 4 Readjust drive roll pressure see Section 3 18 Replace inlet guide contact tip and or liner if necessary see gun Owner s Manual Have Factory Authorized Service Agent check input voltage Have Factory Authorized Service Agent check main control board No wire feed Turn Wire Speed control to higher setting see Section 4 1 Clear obstruction in gun contact tip or liner see gun Owner s Manual Readjust drive roll pressure see Section 3 18 Change to correct size drive rolls see Section 6 4 Rethread welding wire see Section 3 18 Check gun trigger and leads Repair or replace gu
52. er 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 galvanis 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 renferman
53. fault value is 130 Increasing this setting will increase the over torque limit and speed up the remote wire feed speed motor C7 If Aluma Pro push pull gun has a listed SUP value set the power source to match the SUP value Ls complete Parts List is available at www MillerWelds com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Niedz S Disconnect power before maintaining L Maintain more often during severe conditions Y Check Change Clean Replace Reference wanana To be done by Factory Authorized Service Agent Xx Every I 3 Months x Damaged Or Unreadable x Repair Or Replace Clean And Tighten Weld 14 Check Gun Cable Labels Cracked Weld Cable Terminals Every ES Months Inside Unit Clean Drive Rolls 6 2 Overheating Thermistors RT1 and RT2 protect the unit from damage due to overheating If output diode heatsink or IGBT heatsink gets too hot RT1 and or RT2 opens and output stops The fan keeps running to cool the unit Wait several minutes before trying to weld OM 1327 Page 41 Ls complete Parts List is available at www MillerWelds com 6 3 Measuring Input Capacitor Voltage TORQUE TO 17 IN LBS TORQUE TO in El si E Lo J2 4 L4 1 IS f f a A Y y f d f n f f A f y 6 Gi Al 7 S wy S La
54. from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 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 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW Cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Do not weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device 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 ab
55. hen gun trigger is pulled and no arc detected within 3 seconds Turn off primary input power and contact a Factory Authorized Service Agent Help 4 Indicates gun trigger was pulled and held for 2 minutes without a welding arc established or there is a direct short between contact tip or wire and the workpiece Release gun trigger and clear fault condition Help5 Indicates a malfunction in wire feed system and or drive motor overcurrent condition Check for proper spool brake adjustment or obstructions in wire feed system Clean or replace liner wire guides or contact tip Help 6 Indicates a malfunction in wire feed system and or external drive motor overcurrent con dition Spool gun or push pull gun Check for proper spool brake adjustment or obstructions in wire feed system Clean or replace liner wire guides or contact tip Help 7 Indicates input voltage malfunction voltage too high or too low causing unit to automatically shut down Turn off input primary power and check input voltage per primary voltage rating of welder Unit will Operate once input voltage is within specification and power to unit is turned off and back on Help 8 Indicates a malfunction in the secondary power circuit of the unit Check control board PC1 and primary and secondary connections Help 9 Indicates a malfunction in Pulse MIG function Check connection between pulse board and user interface board Replace
56. ing 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 ORIGINAL INSTRUCTIONS PRINTED IN USA C 2010 Miller Electric Mfg Co 2010 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 For International Locations Visit www MillerWelds com GQ Miller
57. ize contact tube Remove barrel assembly before gt and install collet nut threading wire through gun Close top cover on gun Press trigger switch until about 6 in 152 mm of wire is sticking out end of contact tip Cut off wire Close and latch door Ls XR Edge gun drive roll pressure should be set at minimum For XR A Pistol Gun 1 Pressure Roll Assembly 2 Drive Roll 3 humbscrew Lay gun cable out straight Open top cover and lift pressure arm and open pressure roll assembly If not already done remove gun barrel assembly Manually thread wire along drive roll groove Close pressure roll assembly Press gun trigger until about 4 in 102 mm of wire is sticking out front of gun Insert wire into barrel liner and tighten barrel as sembly Install correct size contact tube and install collet nut Reinstall gun cover O Turn On Welding Power Source 4 Pressure Adjustment Knob See final pressure adjustment at bottom of page Remove barrel assembly before threading wire through gun For XR A Pistol Gun Surface Feed wire to check drive roll pressure Cut off wire Close and latch door Tighten knob enough to prevent slipping Tools Needed Turn welding power source Off 7 Do not exceed midrange setting Ref 802 193 A 801 556 Ref 151 666 C OM 1327 Page 25 gt complete Parts List is available at www MillerWelds com SECTION 4 OPERATION 4 1 Control
58. lace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns iiim OM 1327 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals cons
59. lding mode depress the SETUP 6 button once to go to GUN selection Rotate the right knob 9 to select the gun being used Select it for standard MIG gun or select XR A EDGE PITA ALPR for push pull guns or 5PL for spoolgun Depress SETUP 6 a second time to illuminate the PROCESS 3 light Rotate right knob 9 until PULS is displayed Depress SETUP 6 button again to illuminate the WIRE 4 light Adjust left knob 8 to select wire type adjust right knob 9 to select wire size Depress SETUP 6 button again to exit WIRE menu and enter TIMERS 5 menu The TIMERS 5 light will illuminate For description of the TIMERS refer to TIMERS menu see Section 5 3 If crater fill function menus are enabled TIMERS light will stay on to allow for adjust ment of crater parameters and timers see Section 5 6 Depress SETUP 6 button again to exit menus and enter PULSE welding mode OPERATION Adjust right knob 9 for proper Wire Feed speed and adjust left knob 8 to change Arc Length if required Arc length will de fault to 50 if never adjusted previously Re fer to Pulse MIG welding chart for proper Wire Speed setting for metal and metal thickness being welded see Section 4 9 All Pulse MIG programs are setup with the gases listed in the Pulse MIG welding chart If alternate gases are used adjust Arc Length and or Sharp Arc Arc Con trol 7 to adjust arc characteristics ARC LENGTH Arc length can be
60. 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 e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection 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 Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en
61. lectronic equipment perform this installation e Theuseris 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 e Be sure all equipment in the welding area is electromagneticallycompatible 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 lf 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 1327 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Heal
62. lf and others from injury read and follow these precautions 1 1 Symbol Usage 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 DANGER Indicates a hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away 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 tou
63. mission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir 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 de 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 1327 Page 9 OM 1327 Page 10 A complete Parts List is available at www MillerWelds com SECTION 3 INSTALLATION 3 1 Specifications Max Open Amps Input at Rated Output Rated Output Circuit 60 Hz Voltage 200 V 230 V 460 V 575V KVA KW 300 A at 350 A at 90 Sinale Phase 69 61 30 24 13 1 11 2 32 VDC 32 VDC 9 1 7 1 5 0 75
64. n if necessary Have Factory Authorized Service Agent check main control board and user interface board H message appears on voltmeter and ammeter displays to indicate thermistor RT1 or RT2 is open and unit is in an overheated condition see Section 6 5 OM 1327 Page 46 Notes OM 1327 Page 47 SECTION 7 ELECTRICAL DIAGRAM L1 l4 L GRN uu pu p poe O O O O O O WS 1 n 1 1 1 n 5 5 3 3 3 3 L1 ee PC INTERCONNECT BOARD 3 RC2 PLG2 RC23 PLG32 RC46 PLG32 8 F O O PLG 32 CONNECTED FOR 460V OPERATION I MOVE TO RC23 FOR 230V OPERATION n I 8 zx E M MN BDARD RC1 PLG4 v MON MON e oe ult oe d atu t O O O O O O O O D D D D D D D D AN Ni KEES E E E a x a S m N N 10 T2 PLG25 PLG26 A A AA NRA A RAA A 11 o N BLUE lt RC2 14 7 7 1 T pr TIl YEL 480 5 T 29929 2 2 Y 2922 BLUE RC2 12 ia 4 gt B BLUE 13 l RED 230 2 RED uo eas rd c lt RC2 3 CONTROL BOARD 9 gt i RC1 PLG7 f os 200 RED X 15 RC2 1 RC2 PLGB SIC RED 54 RC3 PLG9 a aa Ana 6 YEL e GRN ce 51K RC11 3 RC7 PLG11 B 12 RC8 PLG12 E I RC11 PLG14 B GRN c4 Be RC11 4 RC12 PLG15 10 RC13 PLG16 r 7 RC64 PLG17 25 RCI 2 24VDC 28 RC1 5 I I 27 lt RC1 3 O 460 575 PRIMARY 28 RC1 7 o
65. n unit will automatically shut off For spool guns wire will feed for up to 30 seconds before shutting off If gun trigger is pressed for 3 seconds without striking an arc the displays will show JOG MODE 4 4 Weld Status When trigger is released on a MIG gun spool gun or push pull gun the last actual amperage and voltage will be shown on the displays for 5 seconds The VOLTS and AMPS indicator lights will illuminate under the displays and each value will appear in the corresponding display If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actual values turning either knob will cause actual values in the displays to be replaced by programmed values for adjustment purposes L The 5 second delay after the arc is extinguished for displaying actual weld values can be turned on or off in the Timer menu DISP selection see Section 5 3 4 5 MIG Gun On Demand The guns that can be used with this unit are MIG guns spool guns and push pull guns To switch from one gun to another momentarily press the trigger on the desired unused gun to make it the active gun Once the trigger is pressed the unit will recall stored data and both displays will show the last programmed values for that particular gun If the unit is powered down and back on again the gun last used will become the current active gun 4 6 Pulse MIG Mode Voltage Adjustment In Pulse MIG mode there is no manual voltage adj
66. nale des interf rences arr ter imm diatement l ap pareil 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 SOUDAGE L ARC risque de provoquer des interf rences e nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l 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
67. nd Connecting 1 Phase Input Power PT 18 in 457 mm for airflow Rear Panel Tools Needed SS Ee A A A Installation must meet all National and Local Codes have only qualified persons make this installation Disconnect and lockout tagout input power before connecting input conductors form unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal Warning This unit is either a 200 230 460 ac input voltage model or 460 575 ac input voltage model See rating label on unit and check voltage available at site to be sure it matches the voltage specified on the rating label OM 1327 Page 22 A Do not move or operate unit where it could tip Three Conductor Power Cord Preparation 1 Input Power Cord Strain Relief 2 Input Power Cord 3 Black And White Input Conductors L1 And L2 4 Red Input Conductor 5 Green Or Green Yellow Grounding Conductor 6 Insulation Sleeving 7 Electrical Tape Insulate and isolate red conductor as shown Power Disconnect Device Connections Input 8 Disconnect Device switch shown in the OFF position GND PE Earth Ground Ref 803 543 E 803 766 A 9 Disconnect Device Grounding Terminal 10 Disconnect Device Line Terminals Connect green or green yellow grounding conductor see ltem 5 to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect devi
68. ng Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting 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 Quincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m
69. ng has preset parameters Hot Start can also be set to On manual for customized settings or made inactive when set to Off P VOLTS O PROCESS O WIRE O TIMERS al LENGTH AMPS SETUP Da ARC CONTROL To access the Setup Feature Menu press both SETUP 1 and ARC CONTROL 2 buttons at the same time Left display will initially show arc hours Rotate left knob 3 until AL57 appears in the left display Hotate right knob 4 to select hot start mode as follows Auto default setting for preset hot start parameters Off hot start is inactive On allows customized setting of hot start parameters OM 1327 Page 34 Manual Hot Start Mode When ALS appears in the left display and UN appears in the right display the welding power source is set for manual hot start mode To access hot start parameters press the SETUP 1 button until SPWR appears in the left display SPWR Start Power Range for start power is 100 250 as a per cent of wire feed speed L3 SPWR maximum setting will depend on set wire feed speed and may not allow a setting of 250 under certain conditions STMR Start Time Ref 213 935 A Time range is 0 0 0 5 seconds for hot start to be on STRL Start Arc Length Range for start arc length is 0 99 that changes arc length from shorter to longer RMPT Ramp Time Time range is 0 1 5 0 for the time it takes t
70. o go from hot start to set wire feed speed L The two parameters that will have the largest influence on hot start are Start Power and Start Time These two pa rameters will determine how much heat is provided and for how long at the beginning of the weld To exit this menu press the SETUP 1 button EF A complete Parts List is available at www MillerWelds com 5 6 Setting Crater Fill APS 12 L Crater parameters are welding gun independent i e crater fill can be on for a spool gun and off for a MIG gun When using the same welding gun MIG and pulse programs are independent of each other however crater parameters will be the same for all pulse programs For example if a MIG gun is using the 035 steel pulse program and crater fill is on and parameters are set crater will also be on and the same parameters will be set for a stainless pulse program O PROCESS O WIRE O TIMERS To VOLTS ARC WIRE LENGTH SETUP SPEED AMPS SETUP ARC CONTROL To set Crater Fill select a program and press SETUP 1 until the TIMERS LED turns on Press SETUP again and the left TITI display will show L amp lt and the right display ZZ will show Lrr Rotate right knob 3 to turn crater ON Rotate left knob 2 to change display to ICC y 2 and rotate right knob 3 to set crater wire feed speed Wire feed speed range is 50 700 IPM see Section 5 7
71. ontact your distributor The expertise of the distributor and Miller is there to help you every step of the way GQ Miller Effective January 1 2010 Equipment with a serial number preface of MA 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 equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a N
72. or Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 1327 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 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B
73. orth American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Water Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices CoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HF Units ICE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welder
74. ove procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2010 03 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s 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 DANGER Indique une situation dangereuse qui si on 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 normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir
75. s VOLTS 5 i ee WIRE LS TIMERS in e wi LENGTH SPEED erue 1 FI ARC CONTROL 1 Pulse Indicator Light Ls Pulse only lights if unit has the pulse MIG module and is programmed for pulse MIG 2 MIG Indicator Lights Pulse 1 and MIG 2 illuminate to Indicate weld mode of unit 3 Process Light PROCESS illuminates when unit is in Process select menu 4 Wire Light WIRE illuminates when unit is in Pulse MIG program select menu 5 Timers Light TIMERS illuminates when unit is in Timers menu Use button to access Timers Process and Wire menus 7 Arc Control Button Use button to select either inductance control in MIG welding mode or Sharp Arc in Pulse MIG welding mode 8 Left Knob Use knob to adjust volts in MIG welding mode or change parameter values in Setup 9 Right Knob Use knob to adjust wire speed in MIG welding mode or change parameter values in Setup 10 Left Display de Ref 213 935 A 12 Weld Functions Setup Indicator Lights VOLTS illuminates in MIG welding mode indicating volts in left display can be adjusted Also VOLTS lights to indicate left display is showing actual voltage during welding and for 5 seconds after the arc is extinguished ARC LENGTH illuminates in Pulse MIG welding mode indicating Arc Length can be adjusted SETUP illuminates when a parameter on the corresponding display above the light can b
76. s Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Work Stations Weld Tables No Labor 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor X A gt X A f FH zk HF HF X 6 90 Days Parts Accessory Kits QCanvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 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 INDUSTRI
77. t ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et 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 l soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder 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 e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 1327 Page 6 LE SOUDAGE peut provoquer un 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 peut
78. t www MillerWelds com 3 14 Selecting Input Voltage 200 230 460 Volt Models Only Y NL lt Turn Off welding power E Be sure to reinstall all four screws source Arcones Input securing relinking board in place power and check voltage on input capacitors according to Section 6 3 before proceeding L Check input voltage available at site Ls Incorrect linking can damage unit and void the warranty 1 Voltage Selection View Window Check voltage selected in unit Changing selection is only neces sary if selected value does not match available input voltage 2 Relinking Board PC6 3 Mounting Screws 4 Receptacle RC23 Connection For 230 VAC Input Power 5 Receptacle RC46 Connection For 460 VAC Input Power Move relinking board as needed and connect plug PLG32 in unit to RC23 or RC46 according to input power voltage Tools Needed E e 5 16 in 803 539 C 804 042 A OM 1327 Page 20 EF A complete Parts List is available at www MillerWelds com 3 15 Serial Number And Rating Label Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 3 16 Selecting A Location And Connecting 3 Phase Input Power A Do not move or operate PT 18 in 457 mm for airflow Tools Needed E p c
79. th amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 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 Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice F
80. the SETUP 1 button when the SETUP light illuminates under the Left display OM 1327 Page 38 SRST will appear on the left display and UFF will appear on the right display To prepare the unit for system reset rotate right knob until GN appears on the right display Ref 213 935 A To apply the system reset function press SETUP 1 button and wait until unit completely reboots before performing any other operations gt A complete Parts List is available at www MillerWelds com 5 9 Motor Calibration Function K lt 3 5 PULSE MIG ARC WIRE VOLTS LENGTH SETUP SPEED AMPS SETUP O PROCESS O WIRE Lu TIMERS T ARC CONTROL Perform this function after replacing wire drive motor and or control circuit board The motor calibration function automatically calibrates the wire drive motor to enhance arc starting performance and consistency L gt To obtain the most accurate calibration set up welding power source in MIG welding mode Turn on unit input power 1 Setup Button 2 Left Knob DAD Left Display Right Knob Right Display 6 Arc Control Button Open drive rolls in welding power source and in push pull gun if one is attached to unit a O Simultaneously press Setup and Arc Control buttons Rotate left knob until MCAL is displayed Rotate right knob until YES is displayed Ref 213 935 A Press and hold gun trigger Wire dri
81. umables 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 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks 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
82. ustment instead voltage is synergically aligned with the proper wire feed speed Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage See weld chart in front compartment for proper wire feed speed adjustment according to wire size and type 4 7 Pulse MIG Gun On Demand The spool gun functions slightly different in Pulse MIG mode To switch from one gun to another momentarily press the trigger on the desired unused gun to make it the active gun Once the trigger is pressed the unit will recall stored data and both displays will show the last programmed values for that particular gun For a spool gun the wire speed is taken from the position of the gun potentiometer This wire speed value is automatically adjusted if the potentiometer is moved since the last time the gun was active If the unit is powered down and back on again the gun last used will become the current active gun 4 8 Tip Saver If gun contact tip is directly shorted to the workpiece while gun trigger is pressed the welding arc automatically shuts off after 1 second to prevent wire burnback in the contact tip OM 1327 Page 27 A complete Parts List is available at www MillerWelds com Weld Parameters For MIG Mode 4 9 Occ S c pe9J8JIAWSIIOA 99U919J9H OG1 G ZE S6 S v 001 0 GE 08 S 9 06 0 21 091 0 61 003 S 81 001 S S GEL G SL GLL O SL LYVHO SIN S L S 61 S c 0 8l
83. ve speed will be overridden to 50 IPM for 12 seconds and then to 800 IPM for 12 seconds When CAL ZONE appears on the display release gun trigger DATA SAVE will appear on the display while the calibration data is being stored in the Control board memory Close drive rolls in welding power source and push pull gun This completes the motor calibration function and normal operation can resume OM 1327 Page 39 complete Parts List is available at www MillerWelds com L Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high 5 10 Set Up Push Motor Torque SUP Co al Setup Button Left Knob Left Display Right Knob Right Display 6 Arc Control Button Simultaneously press Setup and Arc Control buttons a FW N OM 1327 Page 40 PULSE MIG VOLTS ct SETUP Eos SETUP O PROCESS O WIRE i O TIMERS I DE ARC CONTROL J 4 Rotate the left knob counterclockwise CCW to find the particular item and rotate the right knob to change the setting The following items can be adjusted by rotating the left knob counterclockwise CCW Set up Push Motor Torque SUP This feature is only active when a push pull gun is connected to the welding power source The SUP setting will adjust the Ref 213 935 A over torque limit of the push motor inside the welding power source The range is 0 250 and the de

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