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Miller Electric 12VS Welder User Manual

1. 17 4 7 Connecting Weld Cable 18 4 8 Weld Cable Sizes manananamanuwnan 18 4 9 Installing And Threading Welding Wire 19 4 10 Display Board PC20 DIP Switch Settings 20 SECTION 5 OPERATION vr en RR e eee veh a RR Yr mem teret a a eros ales 21 5 1 Controls With Melers au aou uoce aus Ce aay IO ORB De ete ye ee eee 21 5 2 Controls Without Meters ls is udo ace bd ae dae owe ete nan don Pre a a 22 5 3 Gun Consumables Information 2288 ceed dae mes eee ea nee a LAC ees 23 5 4 Wire Speed Control Settings sss Soc AAA eq e Same d eie 24 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 0 ococco nnn nnn 25 6 1 RONE MalBtenariee rire ns nine Dr eb ure do ive ie apa ba on Tam Eq oa whee ete acea 25 6 2 Overload Protection And Thermostat Protection 25 6 9 FrogblestiOOHLIO neus c tmr a ale RE er og ial ton d rae de asta trei a dus Late tug 26 Bd DIAQHOSUICS EET 27 SECTION 7 ELECTRICAL DIAGRAM x sau assina hx E o A A atn eee moe 29 SECTIONS PARTS LIST ii A eee ee DOR er re PEE wa dus eer eens 30 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products 7 This informat
2. 1 AUD es out sure faeta 221 347 Grommet BUS BAL sw dixe dt Us CR vt awe ew n s Gp S E 1 AO nimes 600 324 Cable Weld Cop Strd No 4 0 Epdm Jkt 18 in eee ee ee 215 980 Bushing Strain Relief 709 984 Id X1 375 Mtg Hole 1 a8 serene ue letus 2210952 gt s SAGA Wire apr at ROS up det d JS A US ES 1 OM 1500 19 Page 31 Item Diagram Part No marking No Description Quantity Figure 8 1 Complete Assembly Continued Lio EE 207 679 sa ASA 1 BO PRE GS1 226819 Valve 12VDC 1Way 750 14 Thd 2mm Orf 100PSI 1 SE DEE 222 067 Insulator Rear Panel 1 ENEE 070 371 Blank Snap In Nyl 1 093 1 125 Mtg Hole Black 1 DO aid C1 C2 200 606 Capacitor Elctlt 1200 Uf 300 VDC Can 1 39 Dia 2 e ded da E ma 210 133 Bracket Capacitor Support SC12 1 Sa O RR deg 207 678s insulation CADACIOIS i c 9 A9 e bea ie Fr pP alere T p EU dg 1 O tidad 222 109 225 SUDDO SPOOL tus aa tas biliar bilis 1 B sence due uisi 225 069 Hub Spool W Threads 1 DO E 209450 15 NUDE a SE WA a Ui S 1 o ERES 172 919 Knob Brake Adjust 1 OO eee RE Eae a ye ai le LEE 1 Eeer 058 424 Washer Fibre Brake 1 O2 ted se 20
3. 1 PO E 602 009 Screw 250 20x1 25 Soc Hd Hex Gr8 PIN 1 EAS ER no at 010 224 Pin Spring Cs 187 X 1 000 1 DOS is 144 172 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 1 SAIE EE TE 079 625 Washer Wave 500idx0 7500dx 015T Stl Lbs 2 DO aM Er 092 865 Key St 12181230 X 750 au ERE REIHE EU Ses E EEG Eee S 1 SE MCCC 172 076 Carrier Drive Roll W Components Keyed 24 Pitch 1 Cr NODE TR E 121 271 Screw 250 20x 50 Soc Hd Hex Gr8 Pin Lkg Patch 1 EEN 098 615 Hose Sae 187 Id X 410 Od X 20 000 1 DO isis ud 605 308 Ring Ring Ext 500 Shaft X 035 Thk 1 cy dbi ee TT 222 159 X SD TORSION idad 1 CIS ee ae AN 222 390 32 Insulator MOLOE du uice ds boe e oce PD A eae e e Ree 1 S9 ois s W1 224697 Contactor 12VDC W Bus Bars Includes 1 AQ eds PLG5 201665 Housing Plug Skts Service Kit 1 41 TP1 TP2 230471 Thermostat Nc Open 140C Close 110C Snap Action 2 A2 Lu ode ieu te 183 387 Washer Cone 380idx 8600dx 109t Stl Pld 4000Lbs 4 AS eels n pce de RUA 223 862 Nut M10 1 5 17Hex 8H Brs Din 934 2 2 m 222 001 Bracket Mtg Contactor
4. 2x120 2 ea 2 0 2ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F OM 1500 19 Page 18 4 9 Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension 7 Hold wire tightly to keep D it from unraveling 1 Retaining Nut 2 Hub Tension Adjustment Knob Remove retaining ring and install spool so hub pin fits spool hole Re install retaining nut Adjust tension knob so only a slight force is needed to turn spool Threading Welding Wire 3 Pressure Assembly Adjustment Knob Lay gun cable out straight Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun Close and tighten pressure assem bly Press jog switch until wire 3 comes out gun Feed wire against wooden surface and tighten knob so wire does not slip Cut off wire and close door Tighten Ly D Clockwise PA Ref 804 005 B OM 1500 19 Page 19 4 10 Display Board PC20 DIP Switch Settings E DIP Switch Factory Settings X Indicates Switch does not Affect This Function E DIP switch is located behind front panel
5. 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 1500 19 Page 9 OM 1500 19 Page 10 SECTION 3 DEFINITIONS 3 1 Warning Label Definitions Warning Watch Out There are possible hazards as shown by the symbols Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation keep hands and metal objects clear y 2 3 4 4 1 Electric shock can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire
6. OM 1500 19 219 185P m 2007 09 Miller S MIG GMAW Welding Flux Cored FCAW Welding Description Ga V2 ER Wire Feeder SultCase X TREME 12VS CE OWNER S MANUAL File MIG GMAW Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir Y E BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Uyo udhia ete pio ere ex e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And if for s
7. 1 dei S2 216295 Switch Rocker SPDT 4VA 28VDC On Off On 187T 1 a ee EE EN Eeer Nameplate With Meters Order By Model And Serial Number 1 EUN DEE 220 AAZ ER Panel te a EE 1 7 PC20 226373 Circuit Card Assy Meter Suitcase W Program 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 19 Page 34 Table 8 1 Drive Roll amp Wire Guide Kits 2 Drive Roll 7 Base selection of drive rolls upon the following recommended usages 1 V Grooved rolls for hard wire 2 U Grooved rolls for soft and soft shelled cored wires 3 U Cogged rolls for extremely soft shelled wires usually hard surfacing types 4 V Knurled rolls for hard shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Inlet Wire PartNo Type 079 597 053 698 056 193 S 0859 OM 1500 19 Page 35 Notes HOBART INSTITUT OF WELDING TECHNOLOGY Start Your Professional Square East Troy Ohio 45373 Over 80 000 trained Welding Career Now 1 800 332 9448 www weldina ora since 1930 Notes SOCKET WRENCH SELECTION TABLE U S STANDARD SOCKET WRENCH SELECTION TABLE
8. 10 COM 1 RC10 12 gt 122 0228 PC20 I nm o 313 DORO lt _ RC21 PLG21 no lt RC21 1 RC22 PLC22 lt RC5 3 RC9 2 gt 25 14 BUH Gei lt RC8 7 RCS 5 52 2 AA PLG9 RC10 8 gt Jos lt RC8 8 V ae 5 JOG lt RC8 10 MOTOR BOARD PURGE S2 BV JOG 15 47 lt res 2 PEI RC10 5 pyle eure PURGE E O PURGE RC3 PLG3 RC10 6 s PURGE Y RC4 PLG4 RCS PLGS RC10 7 gt T E d XRC5 1 RC6 PLG6 E FRONT PANEL a ow RC7 PLG7 1 77 0 0 0 000 39 45 L 5W TRIGGER RC17 1 CL e Rcz 5 RC8 PLG8 Ee HD1 Z2 FOBK RC9 PLG9 S5 OFF RCI 7 2 lt A SS lt lt RC 3 3 RC10 PLG10 75 FIIV 10 COM RC7 1 5 5 0r7 RCI 7 3 lt lt RC3 4 CG L F RONT PANEL W METERS 7 RC7 8 gt Z d HIGH a lt RCB 5 SS 2 nen aen A 419 GE G51 BS LOW p RC7 2 gt lt RC8 6 SOFT START WELD CABLE ON JI RC8 3 S6 102 101 RC7 6 Re dl OFF cum OL RCB 1 BEE A WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD Figure 7 1 Circuit Diagram For Wire Feeder 218 763 E OM 1500 19 Page 29 SECTION 8 PARTS LIST SN Ne Ref 804 007 K Figure 8 1 Complete Assembly OM 1500 19 Page 30 Item Diagram Part No marking No Descripti
9. PLG10 131052 Housing Rept Skts Service Kit 1 d YA PLG22 115 092 Housing Plug Skts Service Kit 1 PTT PLG7 130203 Housing Plug Skts Service Kit 1 PUT PLG8 115 092 Housing Plug Skts Service Kit 1 E PLG5 201 665 Housing Plug Skts Service Kit 1 Ee PLG3 130 203 Housing Plug Skts Service Kit 1 EE PLG4 131 054 Housing Rcpt Skts Service Kit 1 i ues PLG6 115 094 Housing Plug Skts Service Kit 1 EEN PLG9 21 131 055 Housing Rept Skis Service Kit 2 e PLG17 222397 Housing Plug Skts Service Kit 1 PE RC2 080328 Rept W Skts Free Hanging 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 19 Page 32 gt Hardware is common and not available unless listed Ref 804 007 K Figure 8 2 Front Panel Assembly without Me
10. arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 1500 19 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 surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s 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 Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur a proximit e Le soudage effectu sur un plafond plancher paroi
11. as shown OM 1500 19 Page 20 Ref 804 006 A DIP Switch Settings Display Hold ON Displays will hold their last value for five seconds after the trigger is re leased After the hold times out the Voltage Display will show open circuit voltage If the Wire Speed Amps Display is set to display Amps the amperage value will hold after the hold times out preset Wire Speed will be displayed Display Hold OFF Displays will not hold values Immedi ately when the trigger is released the Voltage Display will show open circuit voltage The Wire Speed Amps Display will display preset Wire Speed when the trigger is released Do Not Display Amperage Wire Speed Amps Display will dis play only Wire Speed Display Amperage Wire Speed Amps Display will dis play Amps while welding and Wire Speed while not welding If the hold function is enabled Amps will be dis played during hold also Wire Speed Inches Per Minute Displays Wire Speed in Inches per Minute Wire Speed Meters Per Minute Displays Wire Speed in Meters per Minute Information OFF Information is not displayed Information ON With switch in ON position at feeder power up feeder will display various sets of information Each set of infor mation will be displayed for three sec onds Display Board PC20 Software Part Number Top display will show the first three digits bottom display will show last three digits
12. at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warra
13. before maintaining during severe conditions 3 Months Replace Damaged Or Replace Damaged Unreadable Gas Hose Labels Repair Or Replace Cracked Cables q And Cords 6 Months o Blow Out Or rive Vacuum Inside Rolls Turn Off wire feeder and welding power source Stop engine on welding generator 1 Circuit Breaker CB1 CB1 protects wire feeder from over load Correct problem and reset CB1 Close and latch door Thermostat Protection Unit has internal thermostat protec tion and will not feed wire if over heating occurs see Section 6 3 Internal Side View Ref 804 006 B OM 1500 19 Page 25 6 3 Troubleshooting Trouble Remedy Wire does not feed open circuit voltage available Check circuit breaker CB1 Reset CB1 Unit overheated Allow unit to cool Check sensing lead connection Check gun trigger plug connection Check gun trigger See gun Owner s Manual Have Factory Authorized Service Agent check Control board PC1 Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or worn drive roll see Section 4 4 Remove weld spatter around nozzle opening Replace contact tip or liner See gun Owner s Manual Change to correct size and type drive roll see Section 4 4 Incorrect size or worn wire guides
14. du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Si l 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 talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante 17 Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un post
15. extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers Arc rays can burn eyes and injure skin Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Become trained and read the instructions before working on the machine or welding Do not remove or paint over cover the label OM 1500 19 Page 11 3 2 Manufacturer s Rating Label For CE Products U 110 V du 10 0 A Us 110V 15 425A X 60 Ref 181 678 804 005 A 3 3 WEEE Label For Products Sold Within The EU Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information OM 1500 19 Page 12 3 4 Symbols And Definitions 7 Some symbols are found only on CE products gt Output Input V A Amperes Volts X Duty Cycle olo Wire Feed o6 Percent p d Sia Cold Jog Inch To sl Input a wards Workpiece 7 Purge By Gas Fast a Constant Current Circuit Breaker Constant Voltage c Slow Yn Trigger Hold Off om Trigger Hold On 2 eo Increase U Conventional Load H Hertz 2 Z Voltage P EN Read Instructions U 4 Primary Voltage 4 Prim
16. insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s 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 fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 1500 19 Page 5 Il reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur quand on a coupe l alimentation e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant d
17. l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil EEN UNE DECHARGE ELECTRIQUE peut entra ner la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger 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
18. of the Display board PC20 software revision level Motor Board PC1 Software Part Number Top display will show the first three digits bottom display will show last three digits of the Motor board PC1 software revision level Accumulated Weld Time This is the time the feeder has actual ly been used for welding This infor mation will be displayed in two halves First being years and days second in hours and minutes Top display will show years hours bot tom display will show days minutes SECTION 5 OPERATION 5 1 Controls With Meters HOLD POWER V WA A d olo A WIRE SPEED AMPS Front Panel 9 Ze LO olo 7 g ON ojos HI olo 7 CVE Internal Control Panel D D 4 z Er d SiS D Internal Side View ll AAA PE wn ZI TO TE Tt 1 Power Control Switch 2 Trigger Hold Switch Trigger hold allows operator to weld without holding gun trigger To use trigger hold function place trigger hold switch in the ON position The operator must hold the trigger for a mini mum of 2 seconds but no longer than 6 sec onds before releasing it Welding will contin ue when trigger is released To stop welding press and release the trig ger 3 Jog Purge Switch Pressing the Jog switch allows the operator to jog wire without energizing the contactor or gas valve Pressing the Purge switch allows the opera tor
19. 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 A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 1500 19 Page 8 Pour les moteurs essence 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 Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com National Electrical Code
20. specter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES ETINCELLES VOLANTES ris quent de provoquer des blessures EN e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manceuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable P Q S a LES CHARGES ELECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande e OM 1500 19 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuve
21. 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 health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workpl
22. 1 309 Washer Anti Turn 2 EIE AA EE EA 223 814 Label Warn Gen Precaution Suitcase 2 ii 223 815 Label Warn Gen Precaution Suitcase CE Only 2 Ree eee UMA 196956 Label Warning Electric Shock And Pinch Wordless 1 eee EEEE E ee 222 306 Label Warning General Precautionary Static Vert 1 ee eee O 223 034 Label Warning General Precautionary Static Vert CE Only 1 OS a ere 220 805 Nut 750 14 Knurled 1 68Dia 41H NYI 1 OF MENORES 081 895 Nut 010 32 Rubber 75Dia 811 Insert In 38Hole 5 EE 182 445 Nut Conduit 1 000 Npt Pld 1 688 Od X 200Tbk 1 DO 2565 ost RES AIT 208 000 Washer Shldr 260id 0 6300dx 125t 3270dx 062t Nyl 4 Ds oia d inert 222 181 Grommet Scr No 8 10 Panel Hole 281 Sq 031 High 5 A PE AT 222 294 Clip Wire Cord 380 Bundle 250Hole 105 Thk Blk 2 DO ues taa dd dd 211 989 330 FINO AN e 1 ZU ayez Dose das 107 983 Blank Snap In Nyl 500 Mtg Hole Black 1 Til ee uo Bafa gee 221 030 Guide Wire Inlet Anti Wear One Pc 023 To 5 64 1 FEAR aa sea 294 079 23 EIS INDO us Bs saci ate Shi den dune RS diio GRR nus 1 DS a 234074 Clamp RIR EIERE 3 ba de a at eue Du es Rp qu e tulle D eS E eo ade 1 Sate eos ne
23. 1 II Wire size 0 045 Wire Type E71T 1M H 8 Gas Mix 75 25 TT Wire Speed 100 150 200 250 300 350 400 450 500 550 600 650 700 750 Voltage 197 205 225 240 272 280 284 295 Amperage 131 155 170 207 218 236 264 284 J _Wire size 0 052 Wire Type E71T 1MH 8 Gas Mix 75 25 TT Wire Speed 100 150 200 250 300 350 400 450 500 550 600 650 700 750 Voltage 180 185 230 247 260 297 320 332 355 1 J 4 Amperage 140 160 190 225 240 271 300 328 340 ol Wire size 0 062 Wire Type E71T 1M H 8 GasMic75 25 1 E Speed EE jaso soo 600 eso meo 799 Voltage 185 200 233 240 272 Eds ee AAA A When welding in CC mode adjust wire feed speed on feeder and amperage on power source to get desired arc voltage When welding in CV mode adjust wire feed speed on feeder and arc voltage on power source to get desired weld amperage NOTE CV is the recommended mode whenever possible Wire Speed is shown in inches per minute Gas mix is 75 Argon and 25 CO Arc characteristics may vary due to cable length size and type of wire used and gas type Ref 222 307A Notes OM 1500 19 Page 24 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect power CS Maintain more often
24. 22 ON olos Sins D ll p mn m PE wn ZI E TE TE Li Y EB gor HOLD POWER ojo Front Panel 5 HI olo CVE Internal Control Panel 1 Power Control Switch 2 Jog Purge Switch Pressing the Jog switch allows the operator to jog wire without energizing the contactor or gas valve Pressing the Purge switch allows the opera tor to purge gas lines before welding and to preset gas flow rate at the flowmeter 3 Wire Speed Control Use control to adjust wire speed within the speed range selected by the wire speed range switch located on the inner control panel 4 CC CV Switch Use switch to match feeder with the output of the power source 5 HI LO Speed Range Switch Use switch to select speed range High range is 50 to 780 Inches per minute Low range is approximately half of high range 6 Soft Start Switch The Soft Start feature provides a smooth start during most weld conditions When the trigger is pulled the wire speed is approxi mately 25 of the weld wire speed as set by the wire speed control knob After an arc is established the wire speed increases to the weld wire speed When using small diameters wire or with in verter power sources it may be necessary to turn switch off to obtain smooth starts After adjusting the switches close and latch the door before welding Ref 804 006 B 5 3 Gun Consumables Information IRONMATE FC 1260 Consumab
25. 45 wire 202891 052 1 16 wire 202892 1 16 078 wire 202893 5 64 3 32 wire Additional parts available call your local distributor for details Notes 200 007 B OM 1500 19 Page 23 5 4 Wire Speed Control Settings RECOMMENDED WELD PARAMETER TABLE Use this table to set the wire speed setting at the feeder and amperage or arc voltage settings at the welding power source Wire size 0 030 Wire Type ER7OS 6 GasMk7525 1 h Wire Speed 100 150 200 250 300 350 400 450 500 550 600 650 700 750 Voltage 170 171 179 189 193 200 207 212 246 Amperage 65 83 97 116 125 139 153 152 160 III Wire size 0 035 WireType ER70OS6 GasMi7525 Wire Speed 100 150 200 250 300 350 400 450 500 550 600 650 700 750 Voltage 165 172 17 6 190 204 210 240 280 280 Amperage 96 100 137 140 147 160 180 200 213 GL Wire size 0 045 WireType ER70OS6 GasMi7525 8 8 Wire Speed 100 150 200 250 300 350 400 aso 500 550 600 650 700 750 Voltage 165 172 175 205 223 235 285 312 323 Amperage 100 158 168 198 207 232 255 278 306 1
26. E S CURIT LIRE AVANT UTILISATION 5 2 1 JVWITDOIGS TEEN 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 aa dt ace Gia das etd mes Ace Re dut oD as 9 2 6 Information EMP asus cain su doe ele ER Geena a RUE ae haa 9 SECTION 3 D FINITIONS Mi ec Sd rue oor RR RU Da intel a E 11 3 1 Warning Label DetinitiOnS amas cai sua set pie Line ada hae Wa OS dre ser eat RE 11 3 2 Manufacturers Rating Label For CE Products 12 3 3 WEEE Label For Products Sold Within The EU 12 324 oymbols And De INHONS ws oie canta a fied ea dei aus Oe awe E e abe ceat d 13 SECTION 4 INSTALLATION ananas en Reti E eran QUT Da Ed Lira da quis ek es 14 AT SDOCIIIGallOLiS 4 o oar atom e Aa eg OD RR AL EIE ELE ER Er at at 14 4 2 Gun Recommendation Table ii IAA WA nee nent tenn rrr 14 4 3 Equipment Connection Diagram ii LS 15 4 4 Installing And Aligning Wire Guide And Drive Rolls 16 4 5 Connecting Welding Gun And Voltage Sensing Clamp 17 4 6 Connecting Shielding Gas
27. FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit ER FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can cause injury 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 e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards IN dei 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 b
28. 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 telephone 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 II y a eu et il y a encore un certain souci a propos de tels champs Cependant apr s avoir exa mine plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti q
29. 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 avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l
30. Specifications Socket or Wrench Size Zoo Equivalent GE Nul 1 4 in 250 in 3 8 in 7 16 in 5 16 in 3125 in 1 2 in 9 16 in 3 8 in 375 in 9 16 in 5 8 in 7 16 in 4875 in 5 8 in 3 4 in 1 2 in 500 in 3 4 in 13 16 in 9 16 in 5625 in 7 8 in 7 8 in 5 8 in 625 in 15 16 in Tin 3 4 in 750 in 1 1 8 in 1 1 8 in 7 8 in 875 in 1 5 16 in 1 5 16 in 1 in 1 000 in 1 1 2 in 1 1 2 in METRIC Specifications Socket or Wrench Size U S ene DZ Bot Na 6mm 2362 in 10 mm 10 mm 8mm 3150 in 14 mm 14 mm 10 mm 3937 in 17 mm 17 mm 12 mm 4724 in 19 mm 19 mm 14 mm 5512 in 22 mm 22 mm 16 mm 6299 in 24 mm 24 mm 18 mm 7087 in 27 mm 27 mm 22 mm 8661 in 32 mm 32 mm 24 mm 9449 in 36 mm 36 mm Notes 24 GA 0239 22 GA 0299 20 GA 0359 18 GA 0478 116 GA 0598 14 GA 0747 1 8 125 229895 10 GA 1345 3 16 0 1875 1 4 250 5 16 0 3125 024 gt 030 gt gt 035 zl MATERIAL THICKNESS GAUGE 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 paris can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distrib
31. ace use the following procedures OM 1500 19 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 48rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one sid
32. ager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de 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 Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeu
33. ary Current Notes OM 1500 19 Page 13 SECTION A INSTALLATION 4 1 Specifications Type of Welding wire Feed Wire Input Max Wire Input Power Speed Diameter welding Spool NTA Weight P PA Source ss B Range Circuit Rating Ca E Dimensions 9 a Type ang g Rating pacity Solid Steel 023 062 in Length 21 in Constant Sen 50 780 ipm 0 6 1 6 mm 533 mm p ES SE WE EE SE o3 451b 20 4kg Width 9 in 35 Ib 14 110 Current CC mpm Bee eet E 12 in 304 mm 229 mm 16 kg Volts DC DC Power Depending On 0 6 1 3 mm Duty Cycle Source Only Arc Voltage Flux Cored io 15 1 S in 030 062 in 394 mm 0 8 1 6 mm Maximum gun length is 10 ft for solid steel 062 in wire 4 2 Gun Recommendation Table GMAW Hard or Corded Wires FCAW Self Shielding Wires Bernard Q 4015 FC 1260 Dura Flux OM 1500 19 Page 14 4 3 Equipment Connection Diagram Turn Off wire feeder and welding power source Stop engine on welding generator Use only with CC CV DC Power Sources Constant Current CC or Constant Voltage CV Welding Power Supply 2 Weld Cable To Feeder 3 Ground Cable To Workpiece Weld cable and ground cable con nections to power source DCEN DCEP are dependant on wire type 7 Since feeder is not polarity sen sitive there is no need for an electrode polarity switch 4 Workpiece 5 Voltage Sensing C
34. damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance
35. dations for weld cable polarity 2 User Suppled Male Connector 3 User Suppled Female Connector Push female connector over male connector and turn 1 4 turn clock wise 804 004 A EA Weld Output Terminals Turn off power before connecting to weld out Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 put terminals 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 m or Less A Donotusewor dane 45 m 60m 70m 90m 105 m 120 m aged undersized or poorly spliced cables i 10 60 60 100 welding Duty Duty 10 100 Duty Cycle Amperes Cycle Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 aa pis 2 ea 2 0 2ea 3 0 2ea 3 0 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2ea 2 0 2ea 3 0 2ea 3 0 2ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2x120 2ea 2 0 2ea 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120
36. de 1 de sao nce a 216 315 Nameplate JPEE sas assises Eun bem pee decirme dccem ere ttc s 1 AA CB1 083 432 Circuit Breaker Man Reset 1P 10A 250VAC Frict 1 VS rd 147 195 Nut 375 27 54Hex 25h Nyl Flange 62D 1 14 S3 S5 S6 217932 Switch Rocker Spst 4VA 28VDC On None Off 187 Ter 3 A PC1 224675 Circuit Card Assy Motor Control W Program 1 TO eios HD1 218339 Transducer Current 600A Module Supply V 5V 1 dd botes M1 220195 Motor Right Angle 24VDC 145 RPM 37 5 Ratio W Plug 1 DO usb bein 124 778 Knob T 2 000 Bar W 312 18 Stud 1 000 Lg PIste 1 TO stb dodo OR obo 0796944 PIN INGE EE 1 Ano e NER E 151 828 Pit Cotter Halt 042 X 750 robbed a RR abaci Ya tape dtes 3 ii 085 243 Knob Adjust Tension 1 250 Dia X 312 18 Thrd Stl 1 eet 089 477 Spring Cprsn 770 Od X 100 Wire X 715 Pld 1 ZO o nS 085 244 Washer Cupped 328idx 8120dx16gax 125 Lip 1 2 ee 089 562 Fastener Pinned 1 DODD tate ed ie 166 071 Lever Mtg Pressure Gear 1 DD lusu ie 166 072 Spacer Gear 44 era hh a hama aha aea eas 1 P iuh eU E 172075 Carrier Drive Roll W Components 24 Pitch
37. e souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel 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 Eneffectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur
38. e and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the 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 S CURIT LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes Symboles utilis s 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de
39. e toucher les pi ces DES PI CES 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 gt LES FUM ES ET LES GAZ peuvent tre dangereux A N Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e 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 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
40. eaners 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 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 protecti
41. 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 cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils
42. he 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 ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HE Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induct
43. iller 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller
44. ing to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter 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 mi OM 1500 19 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cl
45. ion Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement
46. ion is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 Si European Contact Signature Declares that this product S U itC ase X T R E M E 1 2VS conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC 2006 95 EC Electromagnetic Compatibility Directives 89 336 EEC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 5 Wire Feeders IEC 60974 5 Ed 1 2002 02 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 2 1 Degrees Of Protection Provided By Enclosure IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within Low Voltage Systems Part 1 Principles Requirements and Tests IEC 60664 1 Ed 1 1 The product technical file is maintained by the responsible Business Unit s located at the manufacturing facility dec stat 1 07 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 Protect yourself and others from injury read and follow these precauti
47. l 8 Wire Guide 9 Welding Wire 10 Drive Gear Turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Only bottom drive roll alignment is adjustable Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown Cleaning Drive Rolls Remove drive rolls and clean grooves using a wire brush Ref 804 001 B 4 5 Connecting Welding Gun And Voltage Sensing Clamp Turn Off wire feeder and welding power source Stop engine on welding generator 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob insert gun end into block Position outlet wire guide as close as possible to drive rolls with out touching Tighten knob 4 Gun Trigger Plug 5 Gun Trigger Receptacle 6 Voltage Sensing Clamp Connect voltage sensing clamp to workpiece Internal Side View Ref 804 002 C Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied 2 Shielding Gas Cylinder 7 Shielding gas pressure not to Rear View exceed 100 psi 689 kPa 7 3 Valve 4 Flowmeter Close valve on cylinder when fin ished welding Tools Needed ID 5 18 in Ref 804 003 A OM 1500 19 Page 17 4 7 Connecting Weld Cable From Wire Feeder 4 8 Weld Cable Sizes Rear View Turn Off wire feeder and welding power source Stop 4 engine on welding generator User Suppled Weld Cable Follow wire manufacturer s recom men
48. lamp Connect voltage sensing clamp to workpiece 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on wire type 7 Shielding gas pressure not to exceed 100 psi 689 kPa Ref 804 000 C Notes OM 1500 19 Page 15 4 4 Installing And Aligning Wire Guide And Drive Rolls A lo Gm d e gt f i X 6 S O o a j ON EY Kone Af ON E P Ac e hi NO eN am NE o e ON emm BE ec ral ei LJ i En Installing Wire Guide And Drive Rolls Aligning Wire Guide And Drive Rolls Incorrect Correct Tools Needed 3 16in OM 1500 19 Page 16 Installing Wire Guide And Drive Rolls 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier 3 Drive Roll Slide drive roll onto drive roll carrier Turn nut one click Repeat procedure for top drive roll 4 Inlet Wire Guide Screw 5 Inlet Wire Guide One Piece Anti wear 7 The factory installed inlet wire guide is good for up to 5 64 inch diameter wire Loosen securing screw Align inlet guide so inlet guide screw is centered in groove in guide or so tip is as Close to drive rolls as possible without touching Tighten screw Aligning Wire Guide And Drive Rolls View is from top of drive rolls look ing down with pressure assembly open 6 Drive Roll Securing Nut 7 Drive Rol
49. les 1 Contact Tips 198784 045 198785 1 16 198786 068 072 198788 5 64 3 Goosenecks Includes Liners Liners 198796 6 30 199335 6 30 jacketed 198794 6 50 199332 6 50 jacketed 4 Gun Liners 195731 1 16 3 32 dia 199178 045 dia 198791 2 insulated Nozzles 198801 1 8 stickout 198802 2 stickout 198803 2 3 4 stickout 198800 Thread protector 198798 6 90 199334 6 90 jacketed 198799 straight 8 5 198792 198797 12 30 199336 12 30 jacketed 198795 12 50 199333 12 50 jacketed 198793 These parts are included with gooseneck See Owner s Manual to order separately Ceramic S Locking Screw 195732 10ft 195729 15ft ROUGHNECK Consumables 1 Standard FasTIp 206175 023 206176 030 206177 035 206179 045 206180 052 206181 1 16 206182 068 206183 5 64 1 Heavy Duty FasTip 206186 035 206187 040 206188 045 206189 052 206190 1 16 206191 068 206192 5 64 2 Standard Nozzle 198855 300 400 A 199618 500 600 A 4 Goosenecks 199625 4 5 48 199626 6 48 199627 8 48 213450 6 straight 3 Diffuser 206195 1 8 recess 206196 flush 210664 1 4 recess 5 Insulator 198856 6 Gun Liners 202889 023 030 wire 202890 035 0
50. ncorrectly installed or improperly grounded equipment is a hazard e Do nottouch 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 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 equipme
51. nt provoquer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e 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 e Effectuer r guli rement le contr le et l entretien de l installation e 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 Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur
52. nt according to its Owners Manual and national state and local codes 7 Indicates special instructions e ZS ei 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 different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit accord
53. nty 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 Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com 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 M
54. ody other people or any metal when threading welding wire 3 STATIC ESD can damage PC boards 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 gt Ki 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 If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment
55. ome reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in SU oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web 7 Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MPSS e ER a ae Rae ae ee Ne tad li ie ane een a OT Re Neue 1 162 Are Welding Hazardo 2 ae kaa Ae de RARE alee deu aie ee A qua 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 1 4 1 5 Principal Safety Standards uma de pieced daa dees pa cae badass basin edad nanan ee A 4 156 EMP IBITOFITIS BOTE rita dar n c hfe d o SW nd en V d a ic 4 SECTION 2 CONSIGNES D
56. on WELDING can cause fire or explosion Es 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 e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 1500 19 Page 2 Do not use welder
57. on Quantity Figure 8 1 Complete Assembly RR reu UU Bot Bod Fig 8 2 Panel Assembly Front Without Meters 1 RER O a Fig 8 3 Panel Assembly Front With Meters 1 A Te du ne 221 050 Case Control Feeder Plastic 1 si O 208 015 Handle Rubberized Carrying 1 SR pois 221 051 Chassis Control Box 1 Othe es arene carseat 138 044 Bushing Strain Relief 120 150 Id X 500 Mtg Hole 1 A Uno AS 214 011 Cable Sensing Includes 1 ta re EE 600 848 Wire Strd 12Ga Blk 600v 105C 65x30 Hyp 1990d 16ft DOT RSEN 208 820 vue Clamps WOK suga ps peso ds Bese Oh eee tante Russe 1 OT ELE 221 998 Cable Trigger 25 In Includes 1 oo PLG6 115 094 Housing Plug Skts Service Kit d DECORE UNI PR EN 049 445 Cable Port No 18 2 C Type Sjo Nprn Jkt Sf XD RC2 080328 Rept W Skts Free Hanging l es geo LE 048 834 Conn Circ Cpc Clamp Str RIf Size 11 329 Od 1 A Q 070 654 Bushing Strain Relief 300 Id X 550 Mtg Hole 1 jo 208 076 Pahel Je reat Lomo eter ttes bene obe ne nt de
58. ons 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 The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ds ao ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live I
59. ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment a AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le cable de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en 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 lees e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev ass
60. r 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 Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement re
61. s energized after trigger is released Check contactor W1 to see if contacts are frozen closed Gun trigger is pressed gas does not flow wire is not energized wire feeds If a welding arc is not established in 3 seconds after the gun trigger is activated the unit will feed wire without energizing the contactor or gas valve If the gun trigger is still activated after two minutes the wire will stop feeding This is to prevent complete despoolling of the wire as in the case of a damaged gun OM 1500 19 Page 26 Trouble Remedy Information on display board is not accu Have Factory Authorized Service Agent check Control board PC1 rate Check transducer HD1 and connections and replace if necessary Display on display board does not light Have Factory Authorized Service Agent check Control board PC1 Replace display board Segments on the display board are Replace display board missing 6 4 Diagnostics Error Indicators Shown On Display RED LED on Motor Board PC1 HLP 14 4 Blinks Motor Constant Blinking Overload Error HLP 15 3 Blinks Bus Bar Overheat Error Error Indications Error conditions are indicated by a HLP message on the display or by the blinking of the Red LED on Motor Board PC1 To view the Red LED turn Off power source remove shroud and turn power source On The Red LED blinks in a 2 5 second cycle The number of blinks in this period indicate
62. s the type of error If an error condi tion does not exist on the motor board the Red LED is on steady Communication Error The communication error occurs 2 5 seconds after a loss of communication between the motor board and the meter board The user may continue to weld with this error The error may be cleared by turning power Off wait ing a minimum of two seconds and turning power On Motor Overload Error The motor overload error can indicate that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle The error may be cleared by turning power Off waiting a minimum of two seconds and turning power On Bus Bar Overheat Error The bus bar overheat error can be caused by the arc drawing too much current for too long To remedy this re duce the weld amperage or duty cycle OM 1500 19 Page 27 Notes OM 1500 19 Page 28 SECTION 7 ELECTRICAL DIAGRAM oo cO RR ee ee SI EN AC FENDER LSU NM ee CB 1 S1 OFF PLG10 S1 OFF VOL SENSE LEAD Deeg TE RC10 16 oZ SENSE POWER 15 gt 2 LV SENSE I ON Q ON 1 BLK lt RC6 1 RCI 0 15 gt I V SENSE 15 A V SENSE TRIGGER gt m S 2 lt lt RC6 2 RC10 1 Z4 ud E O RED lt RC4 1 A 25 MES RC10 2 OK RC22 1 HOUSING Labi RC10 3 gt 35 14 CA RO22 3 RC10 10 gt I 10 gt EH 18 cc gc22 METER BOARD lt RCS5 4
63. see Section 4 4 Check wire drive motor brushes Have Factory Authorized Service Agent check control board PC1 Motor runs slowly Check and replace contact tip or liner if necessary Have Factory Authorized Service Agent check Control board PC1 If soft start is not on motor will switch to slower speed if current is not sensed by HD1 When soft start is on motor will run slow until weld current is sensed by HD1 Unit does not switch out of Soft Start Check transducer HD1 and connections and replace if necessary Wire feeds when Jog switch is pressed but not when gun trigger is pressed Check gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Have Factory Authorized Service Agent check Control board PC1 Wire stubbing on low end using a con stant current power source or feeder re sets Make sure CC CV switch is in CC position see Section 5 1 Increase power source inductance setting if available Increase output setting of power source or decrease wire feed speed Gas does not flow or does not stop flow ing wire feeds Check gas valve Check coil voltage and connections of gas valve GS1 Check continuity of coil Replace GS1 if necessary Have Factory Authorized Service Agent check Control board PC1 Clear blockage in gas hose or replace hose Clear blockage in welding gun Wire remain
64. 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 lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 1500 19 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4
65. ters Item Dia Part No Mkgs No Description Quantity Figure 8 2 Front Panel Assembly without Meters Figure 8 1 Item 1 Se Wastani aa 171 007 Knob Pointer 1 670 Dia X 250 Id W Set ScrewSplstc 1 Eo PER S1 111997 Switch Rocker SPST 10A 250VAC On Off Visi Red Rock 1 NN WEE 222 797 Blank Snap In Nyl Rect Mtg Hole Black 1 dau S2 216295 Switch Rocker SPDT 4VA 28VDC On Off On 187T 1 EORR E IN Nameplate Without Meters Order By Model And Serial Number 1 pa ORS Bethe te Sh tom ui 220442 Panel LON EEN 1 M T R1 208399 Pot Cp Std Slot 1T 2 W 10K Linear W Frict Tabs 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1500 19 Page 33 gt Hardware is common and not available unless listed Ref 804 007 K Figure 8 3 Front Panel Assembly with Meters Item Dia Part No Mkgs No Description Quantity Figure 8 3 Front Panel Assembly with Meters Figure 8 1 Item 2 Ex AA 179 851 Knob Pointer 1 670 Dia X 250 Id Push On W Spring 1 es So PT S1 111 997 Switch Rocker SPST 10A 250VAC On Off Visi Red Rock 1 D WEE S4 217 932 Switch Rocker SPST 4VA 28VDC On None Off 187 Ter
66. to purge gas lines before welding and to preset gas flow rate at the flowmeter 4 Voltmeter Displays actual arc voltage or open circuit voltage at the feeder 5 Wire Speed Amperage Meter Displays wire speed in Inches per Minute To display wire speed in Meters per Minute see Section 4 10 Amperage displayed at the feeder is approxi mate Refer to power source for actual am perage To display Amperage see Section 4 10 6 Wire Speed Control Use control to adjust wire speed within the speed range selected by the wire speed range switch located on the inner control panel 7 HI LO Speed Range Switch Use switch to select speed range High range is 50 to 780 Inches per minute Low range is approximately half of high range 8 CC CV Switch Use switch to match feeder with the output of the power source 9 Soft Start Switch The Soft Start feature provides a smooth start during most weld conditions When the trigger is pulled the wire speed is approxi mately 25 of the weld wire speed as set by the wire speed control knob After an arc is established the wire speed increases to the weld wire speed When using small diameters wire or with in verter power sources it may be necessary to turn switch off to obtain smooth starts After adjusting the switches close and latch the door before welding Ref 804 006 B OM 1500 19 Page 21 5 2 Controls Without Meters Internal Side View OM 1500 19 Page
67. 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 Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can
68. ues pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes L4W 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 recouvrir d une housse 2 Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS
69. urez 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 oath 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 l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endomm
70. utor and Miller is there to help you every step of the way ur Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the 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 t

Miller Electric 12VS Welder User Manual

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