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Miller Electric 350, 350P Welder User Manual

1. 28 4 10 Weld Parameters For Pulse Mode 29 TABLE OF CONTENTS SECTION 5 PROGRAMMING 30 5 1 MIG Welding Modes rer coros da da ds 30 5 2 Pulse MIG Welding Mode eer ade dd etaient 31 5 9 MES e freres Li NA AA da 32 5 4 Arc Times Arc Starts Hot Start Aluminum Pulse Only And Crater Fill 33 5 5 Setting Hot Start Aluminum Pulse Only Parameters 34 526 Setting Grater Pl a da ek da lea dd e del NUS 35 5 7 Recommended Crater Fill Parameters 36 5 87 e System Reset as dad dd pA S e der do ERA e dls 38 5 9 Motor Calibration Function 2 39 5 10 Set Up Push Motor Torque SUP Or Reset rES 40 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 44 41 6 1 Routine Maintenance 41 6 2 Overheating cio A A A A A A AAA A qa 41 6 3 Measuring Input Capacitor Voltage 42 6 4 Changing Drive Roll and Wire Inlet Guide 43 6 5 Help DIsplays 5 e oo REESE Fr Cobb rede et ae A AR 44 6 6 Tro bleshootllg tai ES Oe ed A evi RSS 46 SECTION 7 ELECTRICAL DIAGRAM en Inn nmm E n
2. 17 3 11 Installing Gas SUpply o ou eni ROLL ETE Rey hone edge pee EDS ae UV EP RE 18 3 12 Installing Wire Spool and Adjusting Hub Tension 19 3 13 Electrical Servico Guide Sra raias rien ope sey hoe pe day aoe As 19 3 14 Selecting Input Voltage 200 230 460 Volt Models Only 20 3 15 Selecting A Location And Connecting 3 Phase Input Power 21 3 16 Selection A Location And Connecting 1 Phase Input Power 22 3 17 Threading Welding Wire For MIG Gun 23 3 18 Threading Welding Wire For XR Edge XR A Gun XR A Python Or XR Aluma Pro 24 3 19 Threading Welding Wire Through XR Guns 000000 ete eee ees 25 SECTION 4 OPERATION SN ge k kx EG RR AREGIARXAR AR ETD A eA NEE ee EAEE Eaa 26 4 1 Control8 ica A A weet dad OURS eA we eae Ae ea EX EE 26 4 2 MIG M e dE NEE AEN dE REENEN AE EN 26 4 3 JOG MOdG 2 2 eege et ee e te dad AA adage Cave Reeders Ra x AES 26 4 4 Weld Status x deena teats he nn fe ote USE E RE EAE Ea Lae enya EET ERR Mute Exe 27 4 5 MIG Gun On Demandi 2 He onlin suka ga be ea A cae gates 27 4 6 Pulse MIG Mode Voltage Adjustment 27 4 7 Pulse MIG Gun On Demand 44444 444 ree 27 4 8 MP SAVE 46 an auton EE 27 4 9 Weld Parameters For MIG Mode
3. L4 1 O L3 1 ASSEMBLY NO R1 R2 1 UR3 ua me Je o i Ex UR4 3 URS Do O a UR7 L3 Z o Tools Needed C AR shein A 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 A OM 1327 Page 42 F7 A complete Parts List is available at www MillerWelds com 6 4 Changing Drive Roll and Wire Inlet Guide MES 045 Groove q 035 Groove Stamped 035 Tools Needed 5 64 in Se 7 16 in 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible
4. 4L Ig Eus Press gun trigger until about 4 in 102 mm Turn On Mo Welding Power of wire is sticking out front of gun Insert Source wire into barrel liner and tighten barrel as sembly Install correct size contact tube Remove barrel assembly before 77 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 IS XR Edge gun drive roll pressure should be set at minimum For XR A Pistol Gun 1 Pressure Roll Assembly 2 Drive Roll 3 Thumbscrew 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 HIS 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 Nonconductive Surface Feed wire to check drive roll pressure Cut off wire Close and latch door Tighten knob enough to prevent
5. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 1327 Page 2 CND Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work 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 MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implant
6. 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 F7 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 in 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 IS 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 a
7. Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legen
8. Troubleshooting A complete Parts List is available at www MillerWelds com Trouble Remedy No weld output wire does not feed Be sure line disconnect switch is On see Section 3 15 or 3 16 Replace building line fuse or reset circuit breaker if open see Section 3 15 or 3 16 Secure gun trigger connections see Section 3 7 Have Factory Authorized Service Agent check Power switch Have Factory Authorized Service Agent check 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 15 or 3 16 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 17 Replace inlet guide contact tip and or liner if necessary see gun Owner s Manual Have Factory Authorize
9. gt 1 TRIG Zoe Sun 6 i s 8 een gt 42 gt 42 2 TRG RTN RXD RCBL 1 gt I rai xD 8 2 R 22 RC 1 MIG I 0 eo m ER TXD RC52 2 gt lt RCI Z RD wn T1525 ca H I l 1 EI E Y ES i NNN CAPACITOR g 5 GND RC82 5 gt mm dck ON LE SS 9 MODULE Y Y Y YY Y 2l Me T d E RS 485 MOTOR et ees on y ee Weg ts VE ro JERE B Mag m 3 RC2 2 RC1 PLGSO e g a 8 a gt ds RCZ PLG29 SC a H GND 224 242 B OM 1327 Page 49 GND pq mn BLK ii 3 E SR Se cre D O Ce i A 7 O PMZ O I D 2 Q Mhr e 4 C 781 I E 1 E1 c2 B Q RED S O a B El O C11 C12 cts eet AS AS M WS G2 T GRN UD m al 4 Lo m ET DL st ai c1 es S Sg kA RC2 1 E PMi O LEI l l T A toro TL RC2 3 Lal D e EG B f Q PC2 GE A INTERCONNECT BOARD 1 EZ RC2 PLG2 O POS PA IGBT IGBT BOARD BOARD RC1 PLGS RC1 PLG4 mn tmn H 1 H 1 H 1 H 1 5003 2020 E 222 SS RS AAA A AA elxlelx Elxfelx sa s m a a S 12 PLG25 PLG26 EN NAN UIS NAN AW AA oc e Sona lt lt lt Rz T T7 Dod pog n DAN y 888838 88848 88 12 SS SS SS RR EE lt lt lt RC2 12 24VAC 4 T 8 E pei M S R2 3 CONTROL BOARD 15 RG
10. helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding 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 Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline
11. input capacitors according to Section 6 3 before proceeding IS Check input voltage available at site IS 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 803 539 B 804 042 A OM 1327 Page 20 CS A complete Parts List is available at www MillerWelds com 3 15 Selecting A Location And Connecting 3 Phase Input Power 18 in 457 mm for airflow A A 4 DOC ei Oooo odo Oooo DOC DOC paagaa D Rear Panel SS Tools Needed 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 from 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 5 6 T A Do not move
12. is recommended And do not work alone e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions 2 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 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 diffe
13. recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points 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 CS 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 Single Ph 69 61 30 24 13 1 11 2 32 VDC 32 VDC gle Phase 1 7 1 5 0 75 0 5 Sa Aa Duty 34 30 15 12 11 6 11 5 Cycle Cycle s y y Three Phase 1 7 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 023 045 in 030 045 in 035 047 in sd CDM Hirer dr M 0 8 1 1 mm 0 8 1
14. see Section 5 7 button OM 1327 Page 35 EF A complete Parts List is available at www MillerWelds com 5 7 Recommended Crater Fill Parameters Recommended Crater Parameters What Material are You Welding What Process are You Using Steel Stainless Steel Steel 0 Aluminum Aluminum Steel Stainless Steel Steel Aluminum Aluminum Mr CU OM 1327 Page 36 Suggested Suggested Wire Types Shielding Gases Solid or hard E70S 6 Stainless steel ER 308LSI ER 309LSI Metal Core 4043 5356 Solid or hard ER70S 6 Stainless steel ER 308LSI ER 309LSI Metal Core 4043 5356 75 Co 25 Ar Tri Mix 90 He 7 5 Ar 2 5 Co 90 Ar 10 Co 100 Ar 100 Ar 90 Ar 10 Co Ar He Co Tri Mix 90 Ar 10 Co 100 Ar 100 Ar Wire Sizes Diameter 0 035 0 9mm 0 045 1 1mm 0 035 0 9mm 0 045 1 1mm 0 045 1 1mm 0 035 0 9mm 0 047 1 2mm 0 035 0 9mm 0 047 1 2mm 0 035 0 9mm 0 045 1 1mm 0 035 0 9mm 0 045 1 1mm 0 045 1 1mm 0 035 0 9mm 0 047 1 2mm 0 035 0 9mm 0 047 1 2mm 1 2 12 7mm 400 26 7 1 0 300 22 2 0 190 21 5 1 15 180 18 5 1 25 85 40 1 0 75 30 2 0 335 45 1 0 100 35 2 0 75 20 15 E A complete Parts List is available at www MillerWelds com MIG SETTINGS EXAMPLE Wire speed Volts Time 90 13 5
15. spjam 19 14 L IP1UOZUOH 404 SDurjes aouasajas Ssajauesed 189 Up 9 ON LYVHO OI OM 1327 Page 28 A complete Parts List is available at www MillerWelds com CS 4 10 Weld Parameters For Pulse Mode M LYVHO 3STMd 0S SZ m S8 wwg o uu uuzi ebzz e66L epg S94 Sve OLL S84 Gel SZ OSI 00 OSI ug eg O61 DL Ovi Ole OSI 00 sz Sel 00 wwo z ebp o6z osr 00 DL 00 Gel 00 OSI ose wwz e 8 4 ose Ov9 09c oSv osz OSL 00 00 00 uug p 91 SOV 024 Sge oss SZE 00c 00p 00 oop uuw 9 V V oss 06 0S9 oop ose 00s Dk oss uuwuc 6 B E Dk 0S7 SV Dk 009 00s 059 LYVHO 3STMd 9GEG Foie 9SES SEO ev0r v9 Ev0b SEO uoBiy 00L UINUILUN Y oO 0L SVO uoBuy 06 9109 ee Sto XIN HL GEO 200 8H AV Sto 09 OL SEO uobiy 06 Jeeis IPRS SE uuz zL M seg ISL C L CZ osvdsvys QS ua 24D isynvfap 8umojjof ayy uo pasoq 24D s42joumapd 1440y Up SIHVHO QI3A E OM 1327 Page 29 E A complete Parts List is available at www MillerWelds com SECTION 5 PROGRAMMING 5 1 MIG Welding Mode 1 fee T MIG 3 SL VOLTS oon 4 BE PROCESS 7 5 O WIRE Fe TIMERS 6 LE ARC CONTROL 8 9 Ref 213 935 A When the MIG light 2 is illuminate
16. teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconna t 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 reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 1327 Page 8 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Recommended Safe
17. 1 0 aad 3 8 1 4 3 16 1 8 9 5 mm 6 4 mm 4 8 mm 3 2 mm 90 13 5 1 0 90 13 5 1 0 90 13 5 0 75 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 75 15 0 75 75 15 0 75 15 15 0 75 T9 15 1 25 75 15 1 25 75 15 4125 75 15 0 75 350 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 75 30 2 0 90 30 1 0 75 30 2 0 275 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 75 30 2 0 90 30 1 0 75 30 2 0 230 45 1 0 100 35 2 0 73 2011 5 120 30 1 75 105 30 1 50 85 30 1 0 79 30 1 5 90 30 1 0 75 30 1 0 175 50 1 0 100 35 2 0 79 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 75 30 1 0 90 30 1 0 75 30 1 0 150 50 1 0 100 35 1 5 79 20 1 5 120 30 1 50 105 30 1 25 PULSE SETTINGS EXAMPLE Wire speed Arc length Time 1 0 PE 14 ga 2 0 mm 90 13 5 0 75 50 15 1 0 79 15 0 75 T9 15 0 75 75 15 0 75 200 11 0 90 85 30 1 0 75 30 1 0 90 30 0 75 75 30 1 0 130 45 1 0 100 20 1 5 75 20 1 5 120 30 1 0 105 30 1 0 90 16 ga 1 6 mm 18 ga 1 2 mm 90 13 5 075 90 13 5 075 50 15 1 0 75 15 0 75 T9 15 0 75 75 15 0 75 85 30 1 0 75 30 0 75 90 30 0 75 90 30 0 75 115 40 1 0 100 25 1 2 79 20 1 0 120 30 1 0 105 30 1 0 50
18. 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 500 400 Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermistors open 300 250 output stops and cooling fan runs Wait fifteen minutes for unit to cool 225 200 Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 150 WELDING AMPERES 100 10 15 20 25 30 40 DUTY CYCLE 60 Duty Cycle At 300 Amperes 20 08 6 Minutes Welding 4 Minutes Resting 50 60 70 80 90 100 40 Duty Cycle At 350 Amperes 4 Minutes Welding gt 6 Minutes Resting Overheating Minutes Aorv Reduce Duty Cycle sduty1 5 95 217 442 A OM 1327 Page 11 3 3 Volt Ampere Curve A complete Parts List is available at www MillerWelds com 1 Normal Volt Ampere Curves MAXVCLTS The volt ampere curves show the MNVOLTS normal minimum and maximum 90 voltage and amperage output capabilities of the welding power source Curves of other settings fall 80 y b
19. 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the 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 above procedures is recom mended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION fre_som_2007 04 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indi
20. Angle holder to insert hook through bottom slot Drop holder down so that hook exits top slot Ref 803 545 B Ref 803 539 B OM 1327 Page 13 EF A complete Parts List is available at www MillerWelds com 3 7 Installing Welding Gun 2 1 Drive Assembly Er 2 Gun Securing Knob 3 Gun End o 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 o O tighten threaded collar 4 amp Close door o 3 9 ND 4 o va Ref 803 541 B OM 1327 Page 14 F7 A complete Parts List is available at www MillerWelds com 3 8 Connecting Spoolmatic 15A Or 30A Gun SN 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 3 SE E Cl LE ND CE Tools Needed LT 3 4 5 8 in 803 568 C OM 1327 Page 15
21. F7 A complete Parts List is available at www MillerWelds com 3 9 Connecting XR Edge XR A Gun XR A Python Or XR Aluma Pro SN EU LF Be sure to trim liner to proper extension E 3 32 in 2 4 mm d Ke 102 IS XR Edge guns prior to serial no LE079101 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 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 A Ref 803 570 A Ref 803 463 OM 1327 Page 16 F7 A complete Parts List is available at www MillerWelds com 3 10 Setting Gun Polarity For Wire Type Her Wire Drive Assembly Lead Changing Polarity Shown as shipped Electrode Positive DCEP For solid steel stainless steel aluminum or flux core with Positive Negative Terminal Terminal gas wires GMAW Electrode Negative DCEN Reverse lead connections at terminals from that shown above for gasless flux cor
22. 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 electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 1327 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding C
23. Q Miller OM 1327 213 814X 2007 11 Processes MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding rc Description OC E3 EJ Arc Welding Power Source and Wire Feeder Millermatic 350 And Millermatic 350P OWNER S MANUAL Visit our website at www MillerWelds com 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 n U 3 Bl E e This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and e
24. and release gun trigger to reset system to factory default values OM 1327 Page 40 F7 A complete Parts List is available at www MillerWelds com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance 2 y p 2 er ptt A Disconnect power IS Maintain more often CA ES before maintaining during severe conditions Is Mm Check Change O Clean Replace Reference To be done by Factory Authorized Service Agent S GU A A i M Ever ay y e 2 Months Damaged Or Unreadable gt lt Repair Or Replace Q Clean And Tighten Weld Check Gun Cable Labels Cracked Weld Cable Terminals Every E f S Lp Months 1 Q 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 E A complete Parts List is available at www MillerWelds com 6 3 Measuring Input Capacitor Voltage Her 000 000 Bi o c3 TORQUE TO 17 IN LBS Se ok o ke o ES E o C4 oy TORQUE TO 17 IN LBS o L1 2 2 J2 4
25. cit C12 es ES T 7 s GRN Wa Le A 1 le 1 m Des rH a St Ex c1 SEN 20To E RO2 1 RIZ re T E A lots 7 lt RC2 8 RI e DG B PCZ H TN INTERCONNECT BOARD RCZ PLG2 CS RCZS PLGSZ A RCA PLG32 1 ee d 450V 230V ACC RC46 RC23 Sen 5 4 3 BI 5 S 2 BE sy Y EJ a T NOTE ER PCS ee PLG 32 CONNECTED IGBT IGBT FOR 460V OPERATION BOARD BOARD MOVE TO RG23 FOR RG1 PLGS RC1 PLG4 230V OPERATION TRIT TR UT 52092 D 28222 HS RS d Ae A A AW A Elx Els El 36 Els a a a HE m PLG25 PLG26 RAR AR RAR AR A A 5 n E EE Rezu PT PT SR l j SR DANN X 8 8 8 4 8 8 8 8 33 LL Ss 2 Ue nq e coc xx ee 24 1VAC 4 13 lt lt REZ 13 PCI AT gt gt 22 lt lt 14X Rc2 3 CONTROL BOARD Ab gt a e SE gt g 17 5VAC 54 RC3 PLOD EL Re2 4 RC4 PLGS ROS PLG10 e L amp REI RC7 PLG11 g 12 RCB PLG12 19 7VAC RC9 PLG13 10 ve REN PL614 ES RC12 PLG15 RCI3 PLG16 RC64 PLG17 E El RC1 2 24v0C L__ 28 m s IT m E LB enz fe a e a Y 7 1 1 1 N e A aq G r n non E o Er o o o o o o a 2 g E E g 2 2 E 2 Y M M LN Y NA A AM NA al 29 NH 55 34 Q A FM RT1 RT2 KSE T T OUTPUT KET DIQDE HS HS amp WARNING e Do not touch live electrical parts gt e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit Figure 7 1 Circuit D
26. complete Parts List is available at www MillerWelds com IS 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 Or Reset rES APE a O9 e PULSE MIG VOLTS ee SETUP ES AMPS SETUP O PROCESS 6 O WIRE TIMERS 1 e ARC CONTROL 4 Ref 213 935 A Setup Button Left Knob Left Display Right Knob Right Display 6 Arc Control Button Simultaneously press Setup and Arc Control buttons while turning on unit input power at the power switch ar N 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 over torque limit of the push motor inside the welding power source The range is 0 250 and the default value is 130 Increasing this setting will increase the over torque limit and speed up the remote wire feed speed motor IS If Aluma Pro push pull gun has a listed SUP value set the power source to match the SUP value To save settings and exit the SUP menu depress the gun trigger Reset rES Rotate the right knob to select ON Press
27. contact tip OM 1327 Page 27 A complete Parts List is available at www MillerWelds com CS Weld Parameters For MIG Mode 4 9 S Occ GE pe98JeJlAVSIOA 992U9J9J9H i 091 0 6L GLL S 6L OSL S Z1 002 S 8L Sez 0 81 001 SL O L 0 9L S6 S V 4 001 0 SL SEL G SL SS1 0 9L GOL S 8L 08 5 91 06 0 21 SLL OSL 091 681 uulgo ulu6 0 wwz ug ebzz eboz eg epg LYVHO DIIN Ove 0 64 GLE OL S9v SZZ 009 S Ez S S 0 vc 9GEG FOI 0 ns 0Sv 0 61 02S 0 L 099 0 2 008 5 Ez 9GES SEO 0Sc G 6l S0 S L SZ 0 c Sev G c SZV 0 vc vOv FOI 00 c 81 08 2 61 OSv G L 0 S 0 c 00 S Ez vOv SEO uobiy 001 wnutun y 00 04 0 eougjonpu 00 S EZ 0S S vc 001 0923 Scv 0 Zc SZv 0 6c Sv0 uoy 06 8109 elo SEZ 00Z 0SZ3 S 0Zz O0E 0 Z OO0v 0vz erg ees Sie 08 09 eouejonpul SZ2 0 0c Sc 0 Lc S Ge EK OStb 0 Sc GEO unijeH 9506 Jeeis ssajure1s DL 2 91 0L S 4t 00c 0 8t 022 061 AVHdS 3sn Sv0 09 GZ 0 0c eouejonpu 002 S 9L 09c 0 81 S42 9 84 DEI Get S8v S82 0 S GG GEO uoBuy 92 1881S OLL O61 DL 0 02 GIL S O2 002 S Ic Occ 0 c Sv0 0 0c eouejonpu SZ t 0 6 0LZ 0 03 Ovc S Oc 08c S LZ Sc 0 c seo 09 96001 leeis uo z wwz e WWg p wwp 9 WILUG 6 HI t ai Sp I19 Je eby 8 14 HUE V V B E o h IM 9 de N suonisod Hulpjam 40 suol Burpjam zo SAd 13410 404 paj poui aq o p u feui sDuies
28. ments Bero d M erste dull ster nc ow 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 21 OVMDOISSUUNISES ad ed eas E ac ete Ts Se bt iso idu el rid DL 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 9 2 6 Information EMF toco deiso K A A PREX oe AA UE EE 9 SECTION 3 INSTALLATION 22clx I eI e I xc LEX A NENNEN EN sent 11 3 1 Specifications 4 IEEE e Reb I Ai c Ane eo b Rs 11 3 2 Duty Cycle And Overheating 11 3 37 Volt Ampere Curve s Se Re eve UE eve eed ade eed td ade A 12 3 4 Connecting To Weld Output Terminals 12 9 5 Installing Work Clamp sia eR Yaad DR yee RENS ie ep ERREUR E irs 13 3 6 Installing Welding Gun Cable Holder 13 3 72 InstallingWelding GUN ueste eR nn ann a DR PRD Ve PRA EOE NY d 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
29. mixed to suit particular requirements e g V Knurled roll in combination with U Grooved Drive Roll WireGuide Fraction Decima Metric PartNo Type inlet intermediate NDAO0N 056 207 056 209 056 208 056 207 056 207 056 209 Ref S 0025 D FF A complete Parts List is available at www MillerWelds com OM 1327 Page 52 Notes Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the
30. or operate unit where it could tip 3 NG GND PE Earth Ground available at site to be sure it matches the voltage specified on the rating label Rating Label Input Power Cord Disconnect Device switch shown in the OFF position Green Or Green Yellow Grounding Conductor Disconnect Device Grounding Terminal Input Conductors L1 L2 And L3 Disconnect Device Line Terminals Connect green or green yellow grounding Ref 803 543 D 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 CS A complete Parts List is available at www MillerWelds com 3 16 Selection A Location And Connecting 1 Phase Input Power 18 in 457 mm for airflow 4 DOC ei Oooo DOC 2000 DOC Oooo 20000 D Rear Panel A A A Tools Needed 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
31. 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 Le couvercle 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 cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fou
32. 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 OM 1327 Page 32 CS 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 ar LEF 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 Calibration function The software version data and motor calibration func tion are for use by factory authorized service personnel only Do not use the motor calibration function if it appears on the displays e PULSE MIG VOLTS fe SETUP An AMPS SETUP O PROCESS 2 O WIRE Lae O TIMERS 1 ARC CONTROL 3 4 Ref 213 935 A Arc times and number of arc starts are saved in unit memory To view this information press both SETUP 1 and ARC CONTROL 2 buttons at the same time Left display will initially show arc hours Rotate left knob 3 and display will change to show number of arc starts To turn on the Crater Fill display rotate left knob 3 until CRTR a
33. 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 A Do not move or operate unit where it could tip TANG 2 GND PE Earth Ground Three Conductor Power Cord Preparation 1 Rating Label 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 8 Disconnect Device switch shown in the OFF position Input Ref 803 543 D 803 766 A 9 Disconnect Device Grounding Terminal 10 Disconnect Device Line Terminals Connect green or green yellow grounding conductor see Item 5 to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device 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 OM 1327 Page 22 F7 A complete Parts List is available at www M
34. 1 PLG7 LLL REZ 1 RC2 PLG8 u IMAG 54 RC3 PLCO XL RCZ 4 RC4 PLG6 RCS PLG10 LL Re11 5 RC7 PLG11 12 RCB PLG1Z RC9 PLO13 19 ep RC11 K ROT1 4 RC12 PL615 RC13 PLG16 RC64 PLG17 E 2 RC1 2 24VDG L 7K Ro1 5 i e RC1 3 E Y 28 m ELL Re1 7 3 a e a es 7 K 1 T 1 l l 1 d a 3 2 S 5 a B 5 5 5 ec a c Ki 4 a a a oe Ww M E M NA Ae w V sl 29 x 33 34 Q A FM RT1 RT2 RED V BLK T E 4 WARNING e Do not touch live electrical parts T se e Disconnect input power or stop SS engine before servicing Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit OM 1327 Page 50 Figure 7 2 Circuit Diagram For 460V 575V Models PRIMARY JUMPER PLACEMENT 460 575 e O SE AN cl fe HD1 cs m n D1 POSTIVE mom 19 IN 18 nl p ae O Q T4 0 1 2 il RE V cl i JK cz j 7 UE i AAA A Pez Ill R1 ent Ul Il ll co cs Me 20 TD m D _ M Qui 1 pz a NEGATIVE n 18 17 d d ECD O l e c5 VW mn BARE CLEAR BLACK E 3 I RED ARR RAR N H E er e 332157 IN Cc Ur 5 9 OG 0 ow ox x X og BLK WHT RC 2 PUSH
35. 15 1 0 75 15 0 75 79 15 0 75 75 15 0 75 85 30 1 0 75 30 0 75 75 30 0 75 50 30 075 115 40 1 0 100 25 1 2 T5 20 1 0 120 30 1 0 105 30 0 75 30 19ga 20ga 1 05mm 0 9mm 50 15 1 0 50 15 1 0 100 35 1 0 120 30 1 0 Se SC 187 212 A OM 1327 Page 37 IS A complete Parts List is available at www MillerWelds com 5 8 System Reset m e ESI LF Accessing the System Reset function will also allow access to Timer Reset 7 2 and Option Reset 757 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 when the SETUP light illuminates under the Left display PULSE MIG ARC WIRE VOLTS LENGTH SETUP SPEED AMPS SETUP O PROCESS O WIRE O TIMERS 1 me ARC CONTROL Ref 213 935 A A system reset function is available that SRST will appear on the left display and GFF To apply the system reset function press completely resets unit back to all the will appear on the right display SETUP 1 button and wait until unit iginal f ings letel f formi origina actory settings To prepare the unit for system reset rotate Ty etely a before performing any To access this menu turn on welding power right knob until DN appears on the right other operations source then press the SETUP 1 button display O
36. EREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2007 01 Owner s Record Ple
37. M 1327 Page 38 CS 5 9 Motor Calibration Function A complete Parts List is available at www MillerWelds com EE TO PULSE MIG ARC WIRE VOLTS LENGTH SETUP SPEED AMPS SETUP O PROCESS 6 O WIRE O TIMERS l ARC CONTROL 4 Ref 213 935 A Perform this function after replacing wire 3 Left Display Press and hold gun trigger Wire drive drive motor and or control circuit board 4 Right Knob speed will be overridden to 50 IPM for 12 The motor calibration function 9 seconds and then to 800 IPM for 12 automatically calibrates the wire drive 5 Right Display seconds 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 6 Arc Control Button Open drive rolls in welding power source and in push pull gun if one is attached to unit Simultaneously press Setup and Arc Control buttons Rotate left knob until MCAL is displayed Rotate right knob until YES is displayed When fL DONE 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 CS A
38. NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement 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 A 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 Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone etou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la 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
39. PULL SPOOLGUN RO 3 3 gt 35 T 3 lt BMR C RC13 1 gt 38 q C MIR ca co MN AT PCS d WA Tm 45 2 gt 48VDC RC11 10D gt CC AS E FR244 FRI 44 m JP4 PLG2R Jp amp 8 z gt H POT COM Am remo 48 psn AGND I RIBBON CABLE PINOUT Dee we ze SE IPEE e gt 5 D TRIG ENABLE DGND RGI1 Z gt lt uP5 4 JP6 3 gt gt 43 G TRIG RTN 3 CONMAND Am Pei gt gt 22 eso 46 6 25 f 46 lt E FOT EW 5 CONTACTOR m or S m 3 3 tas CONDUCTOR JP6 7 F POT WIPER Dee RIBBON CABLE JP5 5 5 52 40 p Zw PLG 23 17 15V Re Mis 19 15V 47 47 24 POND 35VDC J L JP6 2 gt gt LRG Ek P 8 ae y gt gt EE gt a 2 TRIG eng RxD RC amp 2 1 gt gt lt lt RG1 1 TXD 2 g E 3 di RC 1 MIG 6 E y mp RC62 2 gt LL RC1 2 RXD DEER cn 5 B D msn ep CND doi EES E ER E 2 LL E MODULE Y Y Be ame V V V Y Y 31 32 ME de a RS 485 MOTOR i AA AAA wy gue Jod p A Vi 62 A RC2 7 Sg 29287 LP ae ere 63 a XK Rc2 2 RC1 PLGSO 2089 8 3H lt RC2 PLG29 ee a I 1 e OM PC7 OPTICAL TACH 223 926 B OM 1327 Page 51 SECTION 8 PARTS LIST 8 1 Drive Roll And Wire Guide Kits 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
40. Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Tout
41. achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans 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 SA Eo LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester a dista
42. 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 CS 5 3 Timers A complete Parts List is available at www MillerWelds com 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 R i The speed of the wire prior to the welding arc 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 PRE The amount of time that the shielding gas will flow after the trigger is depressed and before the welding arc will be allowed to be active Range of setting is from 0 5 seconds Postflow POST 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 5P27 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 3 SETUP SETUP 4 o PROCESS S 5 O WIRE s TIMERS 6 me ARC CONTROL 8 9 Ref 213 935 A Display 2 5 Allows the Wire Speed display
43. ase complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Miller Electric Mfg Co 2007 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 8 Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
44. asy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And 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 d be exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 11 Symbols age it E e oe de watt nde Aastha ERE E ne ms 1 1 25 Arc Welding Llazatrds EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 4 1 5 Principal Safety Standards 0 4 150 JEME Informaltionis stat ro de oan pl
45. at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your
46. avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc 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 in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaui fement ou un incendie Avant de commencer le soudage v rifier e 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 c
47. avigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout 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 c bles blind s Putilisation de filtres de ligne ou la pose de protec
48. be the same for all pulse programs For example if a MIG gun is using the 035 steel pulse pro gram 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 e PULSE MIG VOLTS fe SETUP An AMPS SETUP O PROCESS O WIRE O TIMERS 1 e ARC CONTROL 2 3 Ref 213 935 A To set Crater Fill select a program and Rotate left knob 2 to change display to Rotate left knob 2 to change display to press SETUP 1 until the TIMERS LED TIME and rotate right knob 3 to set crater TDLY for time delay This setting is for spot turns on Press SETUP again and the left time Time range is 0 1 5 0 seconds see or skip welding without crater fill if the arc display will show ER7R and the right display Section 5 7 time is less than the set time Time range is will show GFF Rotate right knob 3 to turn crater ON Rotate left knob 2 to change display to WFS and rotate right knob 3 to set crater wire feed speed Wire feed speed range is 50 700 IPM see Section 5 7 0 0 5 0 seconds i e if TDLY is set for 2 0 seconds weld operation will not go into Rotate left knob 2 to change display to crater if gun trigger is released before 2 0 VOLT MIG program or AREL pulse seconds program and rotate right knob 3 to set either volts range is 10 0 32 0 volts or arc To exit this menu press the SETUP 1 length range is 0 99
49. 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 piece 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 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 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 possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 1327 Page 5 Il reste une TENSION DC
50. ctive 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 adjustment 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
51. d 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 ip for standard MIG gun or select XR A EDGE PYTH RLPR for push pull guns or SPL for spoolgun Depress SETUP 6 a second time to illuminate the PROCESS 3 light Rotate right knob 9 until Dip is displayed for MIG only units NOT USED will be displayed Depress SETUP 6 button again to illuminate the WIRE 4 light This menu is not used in MIG Welding mode Depress SETUP 6 button again to illuminate TIMERS 5 light 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 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 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
52. d 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 17 Change to correct size drive rolls see Section 6 4 Rethread welding wire see Section 3 17 Check gun trigger and leads Repair or replace gun 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 GND LAN rH wi is BLK 3 X SR A zm co u Ce Ce ZE k PMZ O 4 l D 12 Op Lo he EH i E 5 RED 5 A T gone
53. d models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit 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 H
54. e wires FCAW Drive assembly becomes negative 1 Polarity Changeover Information Always read and follow manufacture s recommended polarity LT 3 4 11 16 in Ref 803 541 A OM 1327 Page 17 EF A complete Parts List is available at www MillerWelds com 3 11 Installing Gas Supply oOooo 2000 D Rear Panel Tools Needed oF 1 1 8 5 8 in 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 Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire 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 803 542 B OM 1327 Page 18 EF A complete Parts List is available at www Mille
55. ed Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing 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 cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons
56. 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 North 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 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year
57. efois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les
58. ention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC a 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 alimentation selon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales 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 cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le
59. etween the curves shown 70 60 ul 2 50 H O gt 40 30 20 107 0 r r r r r r 0 50 100 150 200 250 300 350 AMPERAGE 217 443 A 3 4 Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar i Tools Needed 22 3 4 in 19 mm 803 778 A A Turn off power before connecting to weld output terminals Failure to properly connect weld cables may cause excessive heat and start a fire or damage your ma chine Correct Installation Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output ter minal Slide weld cable terminal onto weld 1 2 3 4 Incorrect Installation output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean OM 1327 Page 12 F7 A complete Parts List is available at www MillerWelds com 3 5 Installing Work Clamp 2 1 Work Cable SE 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 SSF 3 4 in 803 540 B 3 6 Installing Welding Gun Cable Holder 1 Welding Gun Cable Holder 2 Wrapper 3 Slots
60. hauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir 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 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 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 Encasde non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact 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
61. iagram For 200V 230V 460V Models OM 1327 Page 48 PC7 OPTICAL TACH m PC7 za mte O O 20 N PARALLEL 480V C3 amp C4 r H 30 N SERIES Rel HDI LI 40 n POSITIVE ru i T 45 O r o e ll NV 21 d i ARAA T AAA Prez IW en IW Cru 22 SI V Ill ce Ill mE zt 42 2 a T O roD 1 LAS L L 2 1 A O zi 1 En a M 18 17 NEGATIVE al j D in O e D YY Ee rH BARE CLEAR BLAGK E ES RED s 5 j RAA ACA D CH E xw TRT N 0 SES SS BLK WHT RC 2 PUSH PULL SPQOLGUN RC13 3 gt 35 e 35 B MIR RC13 1 gt 4 5 C MIR cs co RM PCs d mm L3 x CT 45VDC RC11 1005 d 4 44 gt m lt JP4 PLG2R Jpe 8 gt gt H POT COM 45VDC RCI1 S gt _ lt JP5 2 AGND 1 45 45 RIBBON CABLE PINOUT Pane RCIE 2655 amp K l EE gt gt TIN TENABLE DGND RC11 Z gt E lt uP5 4 Ire gt 43 TRIG RTN 3 CONMAND 425VDC RC11 5 gt gt 22 X JP5 5 es e gt 4 amp E POT KW 5 CONTACTOR 2 Sa gt 39 7 We cr JP6 7 F POT WIPER 11 PPG RIBBON CABLE 4P amp 5 gt gt 40 ANE ZG PLG 23 17 15V ROA J5 18 15V 47 47 24 POND 35VDC L 4P6 2
62. illerWelds com 3 17 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 ANOoaRWND Tools Needed LF 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 o o K o Tighten IS Use pressure indicator scale to set a desired drive roll pressure o D Pressure Indicator Scale D o 4 a TOR I d l Ol OFF Close and tighten pressure Remove gun nozzle and contact tip Turn On assembly and let go of wire Tighten N l Di l WOOD 4 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 B S 0627 A OM 1327 Page 23 E A complete Parts List is available at www MillerWelds com 3 18 Threading Welding Wire For XR Edge XR A Gun XR A Python Or XR Aluma Pro Wire Spool Welding Wire Inlet Wire Guide Dr
63. in 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 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 3 mar SPEED LENGTH 4 Lo PROCESS 7 5 O WIRE ip TIMERS 6 LE ARC CONTROL 8 9 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
64. install ou mis a 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 a 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 courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante Fx Indique des instructions sp cifiques e PF Ce groupe de symboles veut dire Avertissement Att
65. 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 Y Y 4 Low Inductance High Inductance Weld Bead Weld Bead 0 setting 99 setting OM 1327 Page 30 37 5 2 Pulse MIG Welding Mode A complete Parts List is available at www MillerWelds com When the PULSE MIG 1 2 is illuminated the unit is in Pulse MIG Welding mode SETUP To enter Pulse 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 ip for standard MIG gun or select XR A EDGE PYTH RLPR for push pull guns or SPL 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 aga
66. ive Roll Intermediate Wire Guide Outlet Wire Guide Pressure Adjustment Knob Gun Conduit Cable Lay gun cable out straight S 4 0 NOOA Co ND Tools Needed COP gt IMPORTANT LF Hold wire tightly to keep For Aluminum Push Pull welding it from unraveling Thread hub tension nut loosely 2 218243 A Pull and hold wire cut off end IMPORTANT For Aluminum Pressure Indicator Scale Push wire thru guides into gun continue to hold wire Close and tighten pressure f re indi r Scal assembly and let go of wire 7 Use pressure indicator scale to set front drive roll pressure to 1 and rear drive roll pressure to less than 1 See Section 3 19 for threading welding wire through XR guns Ref 803 544 A 218 243 A 218 244 A S 0627 A OM 1327 Page 24 F7 A complete Parts List is available at www MillerWelds com 3 19 Threading Welding Wire Through XR Guns Pa For XR A Edge Gun A Welding wire is electrically live when gun trigger is used to jog wire IS Refer to Section 3 18 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
67. ltage 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 be adjusted WIRE SPEED illuminates in either Pulse MIG or MIG welding mode indicating wire speed can be adjusted in Setup AMPS illuminates indicating welding amps appears in the display instead of wire speed during welding and for 5 seconds after the arc is extinguished TIMERS illuminates when unit is in Timers menu 10 Left Display 6 Setup Button 11 Right Display LF 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 14 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
68. lth hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 1327 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box
69. mized setting of hot start parameters Manual Hot Start Mode When ALST appears in the left display and ON 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 L SPWR maximum setting will depend on set wire feed speed and may not allow a setting of 250 under certain conditions STMR Start Time 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 to go from hot start to set wire feed speed LEF 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 OM 1327 Page 34 7 5 6 Setting Crater Fill A complete Parts List is available at www MillerWelds com 5 e 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 pro grams are independent of each other however crater parameters will
70. n nmn mn 48 SECTION 8 PARTS LIESE ene seit da st A Me edes 52 8 1 Drive Roll And Wire Guide Kits geg is 52 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 A Protect yourself 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 could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text A DANGER Indicates a hazardous situation which if NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away m ELECTRIC SHOCK can kill 0 Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whene
71. nce e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ou e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage 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 Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et
72. onductor 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 E A complete Parts List is available at www MillerWelds com 3 14 Selecting Input Voltage 200 230 460 Volt Models Only Her Tools Needed CRE LF Be sure to reinstall all four screws securing relinking board in place 3 S e AS 3 lo O sz gt o gt t 5 eo I a o o s E 2 AO O BE oO o Oe 9 LI scher SENE d ki o B ot E ol 5 16 in A Turn Off welding power Source disconnect input power and check voltage on
73. ontact nearest Factory Authorized Service Agent e 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 e 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 when gun trigger is pulled and no arc detected within 3 seconds Turn off primary input power and contact a Factory Authorized Service Agent e 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 e Help 5 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 e Help6 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 e 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 prima
74. ppears in the left LF The Crater Fill display can be turned display The factory default for Crater Fill a ik SCH Pech GE A display is OFF Wien appears In the right fill is turned on in any program it will display Rotate the right knob 4 until GIN remain on even though it does not ap appears in the display pear in the displays because Crater Fill display is turned off 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 CS 5 5 Setting Hot Start Aluminum Pulse Only Parameters A complete Parts List is available at www MillerWelds com m PE LF The factory default setting for Hot Start is Auto on 350P models The Auto setting has preset parameters Hot Start can also be set to On manual for customized settings or made inactive when set to Off jt s PULSE MIG VOLTS Ed SETUP A AMPS SETUP O PROCESS 2 O WIRE Ke O TIMERS 1 e ARC CONTROL 4 Ref 213 935 A 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 ALST appears in the left display Rotate 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 custo
75. provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geantle fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures CA e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N tiliser que les pi ces de rechange recom mand es par le constructeur Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio n
76. que des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A 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 A Seul un personnel qualifi est autoris a installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir a distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut 2 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 a la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement
77. rWelds com 3 12 Installing Wire Spool and Adjusting Hub Tension AA Use compression spring with 8 in 200 mm spools When a slight force is needed to turn spool tension is set Tools Needed E Te ee 2 15 16 in 072573 B 3 13 Electrical Service Guide A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are 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 200 230 460 575 200 230 460 575 Input Amperes At Rated Output 69 61 30 24 34 30 15 12 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker Time Delay 2 80 70 35 25 40 35 15 10 Normal Operating 100 90 40 35 50 45 20 15 Min Input Conductor Size In AWG 6 8 10 12 10 10 14 14 Max Recommended Input Conductor Length In Feet Meters an Ge Ge e A Ge E SC Min Grounding Conductor Size In AWG 4 8 8 10 12 10 10 14 14 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 C
78. rches 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 ue 1 L EMPLOI EXCESSIF peut SUR CHAUFFER L QUIPEMENT pa e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal Se e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter un cran facial pour prot ger le visage ei les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les o circuits imprim s SIS So N e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures 3 ei e Nepas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande OM 1327 Page 7 LES FILS DE SOUDAGE peuvent
79. rent machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns i 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
80. ry voltage rating of welder Unit will operate once input voltage is within specification and power to unit is turned off and back on e Help 8 Indicates a malfunction in the secondary power circuit of the unit Check control board PC1 and primary and secondary connections A complete Parts List is available at www MillerWelds com e Help9 Indicates a malfunction in Pulse MIG function Check connection between pulse board and user interface board Replace 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 e 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 e MM 350P When unit is turned on this display indicates that pulse option is installed and operational MM350 When unit is turned on this display indicates that unit is either a MIG only machine or pulse option is installed but not operational e 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 CS 6 6
81. s to store move or ship PC boards SS N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL STATIC ESD can damage PC boards a MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place a e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained
82. slipping Tools Needed 9 9 H pping A Turn welding power source Off F EF Do not exceed midrange setting Ref 802 193 A 801 556 Ref 151 666 C OM 1327 Page 25 CS A complete Parts List is available at www MillerWelds com SECTION 4 OPERATION 4 1 Controls CH usos T MIG Es 3 TS vours GEN SETUP eo AMPS SETUP 4 EN PROCESS 5 5 i WIRE O TIMERS 6 e ARC CONTROL 8 9 Ref 213 935 A 1 Pulse Indicator Light LF 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 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 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 vo
83. 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 renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit
84. to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard d e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit nn nn e d a FLYING SPARKS can cause injury y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N J e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxe
85. utting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human hea
86. ver the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the 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
87. without touching Tighten screw 3 Intermediate Guide 4 Drive Roll IS 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 IS U Grooved drive rolls are re quired for feeding aluminum wire 5 Drive Roll Securing Nut Turn nut one click to secure drive roll 802 520 B OM 1327 Page 43 E A complete Parts List is available at www MillerWelds com me o mei 9 mei d Displays a jog wire feed speed OM 1327 Page 44 CS IS All directions are in reference to the front of the unit All circuitry referred to is located inside the unit e HelpO Indicates overheating on left side of unit displays flash between OVER TEMP and HELP 1 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 C

Miller Electric 350, 350P Welder User Manual

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