Home

Miller Electric 1000 Welder User Manual

1. 1 sire We A CB1 2 093 995 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 TO lt AA HOS 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 saan ae re eee eer 191 335 RECEPTACLE CAPACITOR w leads includes 1 due RC8 143976 RCPT w SCKTS service kit 1 a C3 6 13 14 097 749 CAPACITOR cer disc 05 uf 500 VDC strip 4 EER EEIE dys CP EM 190 958 2 AINE es TON ara tada draps vetta OU ain ds 1 SPC MUS 2 4 D iiia 128 750 CAPACITOR cer disc 1uf 500VDC 3 dl ove ata e 190961 TERMINAL single stud 1 Tui 190 960 TERMINAL double stud 2 egw WE wi Edid R4 5 136 076 RESISTOR WW fxd 30W 200 ohm 2 p m C 161 303 SPRING cprsn 600 OD x 072 wire x 1 500 lg 3 o Cech ce he ee 191 210 PLATE control lower 1 1 Bp A ata 159040 BLOCK Tem 20A T2P ew zd oos cr ER E ERR 1 PUNCTI ERE RENS 162 828 PANEL mtg rcpt terminal strip 1 PN r RI RE 070 371 BLANK snap in nyl 1 093 1 125mtg hole 1 Tei PT 217 865 LABEL warning electric shock and reduced air 1 PL ce conv ain cee 179 563 LABEL electric shock reduce air flow CE models only 1 pac O dsd ate i
2. 800 696 A Figure 8 3 Rectifier SCR Main 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 2223 Page 32 No Mkgs NO Description Quantity Figure 8 4 Panel Rear w Components Figure 8 1 Item 21 E MU ns 132 101 CHAMBER plenum 14 in motor mount 1 cem 605 799 BLADE fan 14 in 5wg 30deg 500 bore CW 1 nud T 191692 PANEL TOU da ada 1 TTL A ee ee 168343 HINGE door primary 2 UR Nr ie 191 553 DOOR primary ACCESS gt 1 acte rr rh TS nie 1 TE DE 217 733 LABEL warning electric shock amp input power EN FR 1 xis ON spa tado deem eee 179 290 LABEL warning electric shock input connection CE models only 1 axo Uf Bienes CA 097 459 RESISTOR WW fxd 375W 20 ohm 1 aero ads FM 032 605 MOTOR 1 4HP 230VAC 1625RPM 50 60Hz 1 aC 183 167 CONNECTOR clamp cable 2 000 os 1 ICS Hardware is common and not available unless listed 802 298 A Figure 8 4 Panel Rear w Components 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 Manufactu
3. 10 volts dc 1 volt per 10 arc volts OUTPUT 115 volts 15 amperes 60 Hz ac Protected by circuit breaker CB1 115 VOLTS AC CONTACTOR J J Contact closure to completes 115 volts ac contactor control circuit GND K K Chassis common G i Circuit common for 24 and 115 volts ac circuits N L REMOTE POWER ON OFF To remote On Off switch R N Voltage sensing signal from Negative weld output terminal REMOTE VOLTAGE SENSING i 1 P Voltage sensing signal from Positive weld output terminal Not Used OM 2223 Page 17 4 10 Connecting Remote Control A Turn off power before con necting to receptacle 1 Remote 14 Receptacle RC8 Connect remote control to RC8 If plug does not fit wire cord to terminal strip 1T A Turn Off power before open ing terminal strip cover 2 Terminal Strip 1T 3 Remote Control Cord 4 Strain Relief Customer Supplied Secure cord in strain relief Reinstall and secure access panel Close door DM IN DN _ al C E Dl JA B NP 77 76 75 32 2 Ref 802 295 Ref S 0004 A S 0750 4 11 Electrical Service Guide A 1000 Ampere Rated Welding Output 60 Hz Input Voltage 230 460 575 Input Amperes At Rated Output 180 90 72 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 225 110 90 Normal Operating 2 250 125 110 Min Input Conductor Size In AWG 7 3 0 3 4 Max Recommended Input Conductor Length In Feet Meters eue 337 103
4. 438 134 Min Grounding Conductor Size In AWG 4 4 6 6 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 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 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 2223 Page 18 B 900 Ampere Rated Welding Output 50 Hz Input Voltage 380 400 440 Input Amperes At Rated Output 101 96 87 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 125 110 100 Normal Operating 2 150 150 125 Min Input Conductor Size In AWG 7 2 3 3 Max Recommended Input Conductor Length In Feet Meters duo o Ke Min Grounding Conductor Size In AWG 4 6 6 6 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 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 Conductor data in this section specifies co
5. A Be careful when placing or moving unit over uneven surfaces 4 7 115 VAC Receptacle And Circuit Breakers A Turn Off power before connecting to receptacle 1 115V 15A AC Receptacle RC9 Power is shared between RC9 Re mote 14 receptacle RC8 and termi nal strip 1T see Section 4 10 2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects 115 volts ac portion of RC8 1T and RC9 from overload CB2 protects 24 volts ac portion of RC8 and 1T from overload Press button to reset breaker Ref 802 295 OM 2223 Page 16 4 8 Weld Output Terminals And Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Total Cable Copper Length In Weld Circuit Not Exceeding aad AT as a5 m 60 m 70 m 80 m 05 n a 20 n connecting to weld output Welding 10 906 go 100 terminals Amperes Go Duty Cycle aal Uy eye EE 100 4 4 4 3 2 1 1 0 1 0 150 3
6. Close door before turning on unit 1 96 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 3 5 Manufacturer s Rating Label For CE Products ISO IEC 974 1 100A 24V 1250A 44V 100A 24V 1250A 44V 1250A DE U 400V limax 128A lieti 91A 3 50 Hz U 440V laa 117A lier 83A 199 982 A 3 6 Symbol Definitions Panel Local CV Submerged Arc Head Operator s Welding SAW Manual Line Connection Voltage Input Rated Supply Voltage Rated No Load Percent Voltage Average Conventional Load Voltage Rated Welding Current Protective Earth Ground 3 Phase Power Source With AC DC Output Maximum Effective Supply Current Temperature Air Carbon Arc Cutting CAC A Degree Of Protection Gas Metal Arc Welding GMAW e BOER CH For label location see Section 4 4 Direct Current DC Three Phase Duty Cycle Circuit Breaker Rated Maximum Supply Current Ventilating And Air Circulating Fan Shielding Metal Arc Welding SMAW OM 2223 Page 11 SECTION 4 INSTALLATIO
7. RCII PLC11 o 32V MMN V V V V V V V V V c c c Y amp D BACH 55 73 74 75 zie 47 Y V V V V xQ O P O S amp lt lt N BL T CR2 CR2 4 K lO 43 T 79 E g pu RED S47 uo e ol VF T de E qo X a S 42 E o A lt lt PLG7 i RCS 5 6 7 1 2 RC7 PLG2 J 3 gt BR GR SIL a B 2 Gv 5 KC PLA 77 76 43 11 13 12 4 27 LE 43 PLT IS Oo000000000 7 1 DUTPUT 7 amp AOS zie TC E D J A B N P K ONTROL Low vd N CR5 REMOTE 24NAC q L OUTPUT REMOTE GND O CONTROL CONTACTOR E Z 43 115VAC REMOTE REMOTE VOLTAGE Gl CONTACTOR SENSE 7 O pi 76 77 47 4G 8 C3 C6 C14 1 CR4 IS USED WITH GROUND CURRENT L__SENSOR OPTION 73 9 S T 10 RC8 RC8 l K GA J B D E C F H 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 POSITIVE HIGH 1 INDUCTANCE POSITIVE LOW INDUCTANCE NEGATIVE ZON J O L REMOTE POWER ON OFF 218 516 B OM 2223 Page 27 for 50 HZ Model ircuit Diagram Figure 7 2 C SECTION 8 PARTS LIST ICS Hardware is common and not available unless listed es Hf 27 D MEA A Y G REA 32 7 st N A 802 296 B C Figure 8 1 Main Assembly OM 2223 Page 28 50 Hz Models Only No Mkgs NO D
8. 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 Head and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do notinstall unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit 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 lfusing lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e 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 MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WEL
9. the Am perage Voltage control setting determines weld amperage For remote control place switch in Re mote position and connect remote device see Section 4 10 NOTE Hot Start is not energized when switch is in the Remote position 8 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of out put place switch in Remote position and connect remote device see Section 4 10 A Weld output studs are energized only when Output switch is in On position or while welding A Turn Off power before connecting re mote device OM 2223 Page 23 SECTION 6 MAINTENANCE 8 TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect power before maintaining 3 Months Replace Repair or Clean and unreadable replace tighten weld labels cracked weld terminals cable 6 Months Blow out or vacuum inside During heavy service clean monthly 6 2 Fuse F1 A Turn Off power before open ing rear access door 1 Fuse F1 See Parts List For Rating Fuse F1 protects control transform er from overload If F1 opens weld output and fan motor stops Re place F1 Tools Needed C Z H0 3 8 in Ref 802 295 OM 2223 Page 24 6 3 Troubleshooting Trouble Remedy No weld output unit completely inoperative pilot light PL1 off Place line d
10. 16 4 7 115 VAC Receptacle And Circuit Breakers 16 4 8 Weld Output Terminals And Selecting Cable Sizes 17 4 9 Remote 14 Receptacle And Terminal Strip 1T Information 17 4 10 Connecting Remote Control 0 ccc tt rn 18 4 11 Electrical Service OUI c usua bosses Sd i wd fe Re Rico ed fe RGR ox ae 19 4 12 Placing Jurperp LINKS suede dre ud de seco heme its de ste iua or ciconia de Sce bebe o tenait 19 2 13 Conneecling Topub POWDOF cui Bras sus Bi sue scel E Rte Scu Or Scb OD ad dee Sce iaa 20 SECTION 5 OPERATION 2 6o anneren pN ANEAN e AEREN A E LENS 22 S DEDI Pisis o iud be AM s qM E LM EE REM ts Seta b d E PIENE RUM E 22 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 24 6 1 Routine MAiMenanCer T CT 24 Dae BUSCAR T uso ode aeo a Vo ER M Mw Rd abet ek Ba ee aa uiti oe Dae f tre dois ee x 24 62955 JNOUDIESMOOUNG action RARA EEE A 25 SECTION 7 ELECTRICAL DIAGRAMS 0 cc cece enhn nh hh 26 SECTION 8 PARIS dE il la Lee Sii ich i lee DI isl psi isnt 28 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity For European Community CE Products This information is provided for units with CE certification see rating label on unit Manufacturer s Name Miller Electric Mfg CO Manufacturer s Addre
11. 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 Positive Negative 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 UL ERES re 350 1 0 2 0 3 0 40 220 230 230 2 4 0 aM 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 600 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 Positive Low Inductance used for all applications 700 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 Positive High Inductance 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 cs NE 2 2 0 2 3 0 2 4 0 3 30 3 40 4 40 4 4 0 1000 2 2 0 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 1250 2 3 0 2 4 0 3 3 0 4 3 0 4 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes S 0007 E 4 9 Remote 14 Receptacle And Terminal Strip 1T Information Socket Terminal Information OSSA OUTPUT A A 24 volts ac Protected by circuit breaker CB2 24 VOLTS AC CONTACTOR B B Contact closure to A completes 24 volts ac contactor control circuit C C Command reference 0 to 10 volts dc CC 10 volts dc CV REMOTE OUTPUT CONTROL D D Remote control circuit common E E 0 to 10 volts dc input command signal from remote control F E f k 1 1 vol 1 A V AMPERAGE Current feedback 0 to 10 volts dc 1 volt per 100 amperes VOLTAGE H i Voltage feedback 0 to
12. Included w T1 fan control circuit 2 Ln PLG6 168847 CONNECTOR amp SOCKETS 1 Ces ee RC6 168845 CONNECTOR amp PINS l TA PLG13 218413 HOUSING plug pin skt service kit 1 pn e ees RC13 218408 HOUSING plug pin skt service kit d P 161 294 BRACKET mtg rectifier 2 T A Figure 8 2 PANEL front w components 1 dise ORI ces 191 257 RECTIFIER scr main Figure 8 3 1 EEE titan d PLG7 152249 CONNECTOR amp PINS ucc e e x l TP RC7 168 846 CONNECTOR amp SOCKETS 1 DA DA D D de 010 467 CONNECTOR clamp cable 1 250 1 Eo TUS Gh MERE 221959 CAPACITOR ASSEMBLY 50 Hz Models Only includes 1 idc ead reuerti s 163 535 CAPACITOR elctlt 16000uf 60 VDC 6 C 162817 Bus Bar capacitor 2 ee R6 140002 RESISTOR ww fxd 10w 500 ohm 1 E Gun 182 660 BRACKET mtg capacitor 2 mx c TTT 207805 CONTACTOR ASSEMBLY 50 Hz Models Only 1 C EPI 604 536 SCREW 312 18 x 1 75 hex hd pln gr5 pld 2 Part of O
13. Page 2 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 HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks 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
14. a me sores 197 868 SNUBBER ASS uci xdesames watt ed X oo w Run edo ee RC 1 x33 raies A 011 611 SWITCH tg DPDT 15A 125VAC On None On 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 2223 Page 31 Item Dia Part NO Mkgs NO Description Quantity Figure 8 3 Rectifier SCR Main Figure 8 1 Item 33 1 07 12 048420 CAPACITOR cer disc 01uf 1000VDC 6 A 176 168 BAR MtO F clflGr tai et sce Ri den me net 2 E QT COS 166 667 CLAMP spring thyristor rectifier 3 SL OUT 191 248 HEAT SINK rectifier snowflake1 500 eene 6 5 SCH1 6 148091 THYRISTOR SCR 865A 300V hockey puck 6 TE cp 191 247 HEAT SINK rectifier snowflake3 000 3 uuo d und Ra d eT MC 191246 CLAMP thyristor rectifier 8 187 3 TP PLG1 svea 158 720 xs CONNECTOR amp SOCKETS waved und ped RR 1 CA Tras 192 91 zx THERMOSTAT frec flef 2 5 separa Ioa e cae Taceo xy d Lade dali TP6 168894 THERMOSTAT rectifier fan control circuit 1 ICS Hardware is common and not available unless listed
15. d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer 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 Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou mal piss s e Ne pas s enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un Cable distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode d une autre machine som fre 8 03 Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance Il y a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de connaitre les me sures prendre pour viter tout danger e Nutiliser que du mat riel en bon tat R p
16. gaz comprim de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire 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 cir cuits lectriques e Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N utiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes D tourner la t te lorsqu on ouvre la soupape d une bouteille Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz compri m les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit 2 3 Autres symboles relatifs a l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle Ne pas installer l appareil proximit de produits inflammab
17. graisseurs e Netravailler dans un espace clos que s il est bien ventil ou porter un respirateur adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble e Ne pas souder 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 former des gaz hautement toxiques et irri tants e Ne pas souder de m taux munis d un rev tement tels que la t le d acier galvanis e plomb e ou cadmi e moins que le rev tement n ait t enlev dans la zone de soudage que l endroit soit bien venti l et si n cessaire porter un respirateur adduction d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques lorsqu on les soude OM 2223 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage
18. l phone 617 770 3000 site Web www nfpa org et www sparky 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 l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiquespendant le soudage ou le coupage OM 2223 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail re
19. lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger e Ne jamais toucher aux pi ces lectriques sous tension e Porter des gants et des v tements de protection secs et exempts de trous e GSisoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre e Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l o on risque de tomber e Nese servir d une source de courant alternatif QUE si le proc d de souda ge l exige e Si l utilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil Couper tiqueter l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor mes de s curit e Installer et mettre la terre correctement l appareil conform ment son manuel
20. 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 neus Ate be reales 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 catalog 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 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ths Symbol USAS radicadas br OE ae Peta eee See om as i ER wens 1 1 27 Are Welding Hazards a ack shade iso ode 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 14 Galifornia Proposition 65 Warnings acia a 3 1 9 Priticipal Sale Standards nn ns dd ana E NE ads 4 1 62 IES e A atte OR AN asit e busca deer Noir d 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 29 3 o uico me hod doa Ped cc heo eh n Ree dec dica a
21. 400 500 600 700 800 900 1000 80 70 60 50 40 Volts 30 20 10 o Amperes va curve1 4 95 ST 199 986 A ST 190 973 OM 2223 Page 13 4 4 Selecting A Location Movement Location And Airflow INPUT SERIAL NO STOCK NO VOLTS AMPERES KW PHASE OM 2223 Page 14 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Non CE Models Only Use rating label to determine input power needs Label located under front access door 4 Plate Label CE Models Only Label located under front access door 5 Rating Label CE Models Only Use rating label to determine input power needs Label located on rear access door see Section 3 5 6 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 5 Dimensions And Weights 4 Holes 800 453 A 801 530 Dimensions A 30 in 762 mm Including lift eye B 23 in 584 mm C 38 in 966 mm Including strain relief D 35 in 889 mm E 1 1 4 in 32 mm F 21 1 8 in 537 mm G 1 1 8 in 29 mm H 7 16 in 11 mm Dia Weight 1000 Amp Models 644 Ib 292 kg 1250 Amp Models 650 Ib 295 kg OM 2223 Page 15 4 6 Tipping
22. DING 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 m 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 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 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 Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tig
23. LITY 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 1 05 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 Weld
24. N 4 1 Specifications Amperes Input at Rated Amperes Input at Rated Load Output Load Output Model tonto Range DC ocV bc 60Hz Three Phase 50 Hz Three Phase 230 V 460 V 575 V 380 V 400 V 440 V KVA KW 100 1250 A In CC 3008 1000 A O 44 Mode 180 90 72 73 93 Volts DC 10096 66 VDC 9 8 2 9 2 4 3 2 0 5 Amp Duty Cycle 10 60 V In CV Mode 100 1250 A In CC 900 A 44 Mode 101 96 87 66 3 48 4 1290 Volts DC 100 66 VDC 52 50 45 34 0 56 Amp Duty Cycle 10 60 V In CV Mode While idling 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding A Exceeding duty cycle can damage unit and void warranty u n U gt lt T m D m O DUTY CYCLE 100 Duty Cycle Continuous Welding Overheating PPP gt gt Minutes OR Reduce Duty Cycle duty1 4 95 SA 191 157 A OM 2223 Page 12 4 3 Volt Ampere Curves Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be A CC Mode tween curves shown 70 r VOLTS 200 400 600 800 1000 1200 1400 1600 AMPERES B CV Mode 100 200 300
25. OM 2223 190 969R January 2005 Miller po Multiprocess Welding i Description a4 sa Arc Welding Power Source C Dimension 1000 1250 OWNER S MANUAL 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 RU E BI Y El ZA eem 7 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 i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick hassle free warranty in the l business and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And N for some reason the unit
26. OTE REMOTE VOLTAGE CONTACTOR SENSE 77 47 45 T T T T RC amp H BR GR SIL 77 M ER ne ie E 1 CR4 IS USED WITH 1 GROUND CURRENT SENSOR OPTION RCE e Disconnect input power or stop engine before servicing For Primary Circuit Diagram Portion refer to the Circuit Diagram located inside the wrapper of the welding power source e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit s 218 515 A for 60 HZ Model ircuit Diagram Figure 7 1 C 2223 Page 26 OM 380 400 440 PRIMARY TEI T UO e S Q 9 GROUND CURRENT gt 27 E SENSE OPTION 2 29 5 O REED 2 E C2 2 T uz D E O C2 og c O amp i 87 pe a 2 9 37 2 m Ji RC6 NN N N NN N N N N N N NNN N 37 E d P Bs Bae QQ iD T7 tN TMNT a ao nm on o RC4 122 727 RC10 1 m UN S555 sag m 7 L RC4 2 gt gt lt lt RC10 4 o E 32v Eg pcd cr eS E OQ 9 D RC4 4 gt gt lt lt RC10 5 9 O B ALK 43 62 RC3 16 PC1 RC4 7 gt gt RC11 5 Ro11 1 gt S S AED 6s OA PLOT ROS PLGS OE A a O S T RC3 17 RC3 PLG3 RCB PLG16 RC4 8 5 5 RC11 8 PC2 RCA PLG4 E E 9 32V Le Rc3 15 RC4 622 X amp RC11 9 AMP VOLT a B Z 47 EK 7 RC4 9 gt lt RC10 2 METER BL IS x Tor y M ME e 2 o BOARD OS AED 335 808 388 3 y L L l1 RCIO PLGIO Cm 5 3 c E c E c E o 5 5
27. Y COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR 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 MERCHANTABI
28. ac d aise 5 2 2 Dangers relatifs au soudage aliaron datos ade due nce dotato iced a Praese Lat 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit 80 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 1 52523 ER ER AIRE ER ER R NH RRR RNA RR IRIS RR ELI 9 3 12 Genera Freca tionary Ee satura datur n dade ve dp vai ev OF ED E WR RP 9 aces Input Connection Label 45 3 taque nop NS mr c pred re dee ea ai ordi e EO 10 3 3 Electric Shock And Airflow Label uua dae dedo pe uh ds ide 10 3 4 Nameplate Safety SymbolS 52 ss is Ride RUE ii nisu Edad aid 10 3 5 Manufacturers Rating Label For CE Products ees 11 SOx iie Be CPC m 11 SEGIHONJT INSTAELALTION 2 pedet Yee nee AA uite SOR Er E E ES 12 Ze pei CallollS s A AN we he VERE M ES 12 4 2 Duty Cycle And Overheating ers over iu N ERN Dew ois SERERE is oe Se NR TENES 12 4 3 Moll Ampere GUIVOS cer is vos evene re Sn vee es A eee ee Se REEF MES 13 4 4 Selecung A LOCAUOM ac oG aora dina ra ien co Big shoe d cod ates Rene whee Bee 14 45 Dimensions ANG Weigh s s xe eoe add Rime chow Rene eS Ens hee RES ete NER ERE KE 15 AG To Gil At RE PE hoe Bene Gabe cane soe Bane eee Mune Rate Eee exon dons hee RES oie ene sib hae
29. arer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e Ne pas connecter plus d une lectrode ou plus d un cable de masse un m me terminal de sortie Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Se tenir distance des fum es et ne pas les inhaler e l int rieur ventiler la zone et ou utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est insuffisante utiliser un respirateur a adduction d air agr e Lire les fiches techniques de sant s curit FTSS et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d
30. cilement passer m me par des fissures et des ouvertures de petites dimensions Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform ment l AWS F4 1 voir les normes de s curit Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu a f vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures ris
31. deas 172587 COVER output stud 1 nee ed R 150 935 1 GEIR SONNO sia ina 3 tl aucun EE EEE 601835 a NUT 10 32 DIS vir id ERR FOE ibid SR 2 T 010913 4 WASHER I3 219 ID DIS Esset aaa eer d Tm 185011 STUD pri bd brs 10 32 x 1 592 1 A eae iaa 088 409 SWITCH tgl DPDT 15A 125VAC On Off On 1 n codes So ii 011609 SWITCH tgl SPDT 15A 125VAC On None On 1 ced COAL OS RIZ tains 198 087 POTENTIOMETER CP std slot 1 T 2W 1K ohm 2 jain A P aa 213605 CIRCUIT CARD ASSY digital meter 60 and 50 Hz Models 1 On PLOTO 153501 CONNECTOR 8 SOCKETS 1 EE EPERE PLG11 148439 CONNECTOR amp SOCKETS 1 aE Aa Ads S 4504 116 592 RELAY encl 24VDG SPDT count de aa tar 1 mo c 192 174 STAND OFF d sei taces dept nes Sore fae e eater eus 4 Tro c T93 704 lt y PANEL front UDDEN aes mute dates kh opea OR Aaa Ey FOR RC I 1 HT NAMEPLATE order by model and serial number 1 s dl EN as 159 039 SWITCH rocker SPDT 15A 125VAC 1 e y A PL2 ws 159522 sa LED yElOW gt cererea a Abi dan 1 Mu Dea R A eed 15905612 CENS LED ClO Ar read daa 1 pe c vv 097 924 25 IKNOB CDOIDIGE siii 224 hte te cil cic eer etri cr es dd 1 Nc A hte ee nn 097922 4 KNOB DOIDIBE stat oe icio e Ear necu Reps is 1 RS Alanna biet
32. elephone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou a Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t
33. escription Quantity 8 1 Main Assembly rcr 179492 PANEL SIJE rain 2 o TTT RS U COVER TOD TTT 1 Low TTT 164 700 BAFFLE oll ck aided cre eeu Eee eho eee actu Statu bU 2 ee TTT 162816 CHANNEL upright front 2 ads lt ane ene te E E AE 191 295 2 GUSSET ASO TTT 2 Te lt cherie rp 162 820 BAR mtg lift eye 2 TW quc 177279 GARE TMI CVC id iii i erai eet ei 1 ET TT 162 990 5 cL Ye 2 dae tenn cde dee ge E RONDE me 1 rr 604 536 SCREW 312 18 x 1 750hexhd gr5 2 TIE 2 DP 134 201 STAND OFF SUPPORT pc card 4 RS LOT ies 162821 xa BRACKET MO LEM ss insu er mu 1 b te eee HD1 148 417 TRANSDUCER current 1000A module 1 bran edo rais PLG14 130204 HOUSING PLUG PINS amp SKTS d D esr E cena ted ta Se cata 191 213 BUS BAR stabilizer slo ec ene 1 Vico AAA PA et oar 1909545 xa FOMABILIZE vue Arena herons N ae ees Wee are ene 1 2 C OEA C21 23 099 519 2 CAPACITOR ics ss uen sare eta or nette P ecu dadas tue ina diane acs 3 xd ciscus A 159042 TRANSFORMER control 50VA 24V 230 460 575 60Hz 1 TES CEPS 122 159 043 TRANSFORMER control 50VA 24V 380 400 440 50Hz 1 o 16 ei TES puna 193 495 PRIMARY BOX includes 1 pr dr GU T2999 Scam D 10 92 A a dedans S
34. essures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage 3 LES ORGANES MOBILES peuvent causer des blessures e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences e Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation Si la Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil Faire r guli rement contr ler et entretenir l installation Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn t
35. for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 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 t
36. g gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 2223 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection fa WELDING can cause fire or explosion E Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from f
37. g properly Have Factory Authorized Service Agent check control board PC1 and connections and replace if necessary OM 2223 Page 25 SECTION 7 ELECTRICAL DIAGRAMS O NEGATIVE ELE n ETA TE1 TI b 3 575V S IC gt EE im O POSITIVE HIGH C4 INDUCTANCE a C7 SCR SCR T O 1 2 sa Fe gt PI DS E 28 O POSITIVE y S lo LOW REED 2 E pq qu CEM c2 INDUCTANCE TURNS T 14 M3R9AS a 10 d B GND C10 C11 C12 L SCR SCR SCR CR2 eR 4 5 6 2 sss P RC4 1 gt lt RC10 4 RC4 222 X RC10 4 S SO RC6 5 PLG13 PLG6 vu 9 J4 o L xD 1 1 W C23 i 32V cre RC4 4 gt lt RC10 5 PC2 RS B ALK 47 6Z lt Rc3 18 PC1 RC4 7 gt E lt lt RC11 5 COE CEN B RED CONTROL BOARD RC4 5 gt gt XX RC11 2 BOARD gt E A 3 gt RC1 12 gt RC1 1 gt RC1 9 gt RC1 10 gt RC3 18 gt RC3 19 gt RC4 10 RC10 l 6 lt lt RC3 17 aara S SOL 6 lt lt RC11 8 RCIO PLGIO 2 4 c 32V i EZ WES RO4 PLG4 RO4 6 222 S RC11 9 O O o B K 43 RC4 8 gt lt RC11 6 W 022 13 Dll ap f RC10 2 2 me y NT E m Loaded 2 Alles gt 2 2 S 2 O eta ar 47 V_V MN oy 29 4 ALL At RC9 47 MESS M MT 79 48 dad k CR2 CR2 77 76 43 11 13 12 4 27 28 43 2 3 IT 0 VR E DI 4 N P K N L A B RC7 bord NF REN TE DANAC RENOTE OUTPUT REMOTE GND POWER CONTROL CONTACTOR QN OFF 115VAC REM
38. h Inductance weld output terminal see Section 4 8 for SMAW or GTAW welding e CV FCAW Mode For FCAW Flux Cored or SAW Sub Arc applications re quiring 1 16 in dia or smaller welding wire 3 Amperage Voltage Adjustment Control When Process Selector switch is in the Constant Current position turn control clockwise to increase amperage Read am perage from outer scale of control When Process Selector switch is in the Constant Voltage position turn control clockwise to in crease voltage Voltmeter value changes as control knob is turned Control can be ad justed while welding 4 Digital Meters With Process Selector switch in the Constant Current position digital meters will read 0 zero with contactor off Digital me ters will display actual output voltage and amperage with contactor on With Process Selector switch in the Constant Voltage position voltmeter dis plays preset voltage with contactor off Volt meter and ammeter display actual output voltage and amperage with contactor on 5 Power Switch With Indicator Light 6 High Temperature Shutdown Light 7 Remote Amperage Voltage Control Switch e For front panel control place switch in Panel position With Control switch in the Panel position and Process switch in the CC position Hot Start is energized for ACA Air Carbon Arc Gouging and SMAW Stick welding When Hot Start is energized higher short circuit amperage helps arc starting After arc starts
39. he 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 2223 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect wor
40. htly 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 lfinterference 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 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive 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 OM 2223 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation
41. ing Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA C 2005 Miller Electric Mfg Co 1 05 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 ur Miller
42. ing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Maxstar 85 140 Spot Welders Load Banks A
43. ipment 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 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 Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e 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 som 8 03 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f 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 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 w
44. ique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre Veiller souder une distance de 100 metres de tout quipement lectronique sensible Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel En cas d interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 2223 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t
45. isconnect device in On position see Section 4 13 Check for open line fuse s and replace if open see Section 4 13 Check for proper input power connections see Section 4 13 Check for proper jumper link position see Section 4 13 Check fuse F1 and replace if necessary see Section 6 2 No weld output pilot light PL1 on Unit overheated Allow unit to cool with fan On see Section 4 2 If using remote control place Output Contactor switch in Remote 14 position and connect remote control see Sections 4 9 and 4 10 If remote is not being used place switch in On position see Section 5 1 Check repair or replace remote control No weld output power switch pilot light on fan off Check for proper input power connections see Section 4 13 Check for open line fuse s and replace if open or reset circuit breaker see Section 4 13 Turn power switch off then back on If no output condition remains have Factory Authorized Service agent check SCR s Limited weld output and low open circuit voltage Check position of Remote Amperage Voltage Control switch see Section 5 1 Check for open line fuse s and replace if open see Section 4 13 Check for proper input power connections see Section 4 13 Check for proper jumper link position see Section 4 13 Clean and tighten all weld output connections Unit provides only maximum or minimum weld
46. k clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT A LIRE AVANT UTILISATION 2 1 Signification des symboles i ldentifie un message de s curit particulier Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Signifie NOTA n est pas relatif a la s curit 2 2 Dangers relatifs au soudage l arc Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apres ne font que r sumer le contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants rm LES D CHARGES LECTRIQUES e peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L
47. les Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que Tanneau de levage pour lever l ap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si on utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil uN T di L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L QUIPEMENT rid e Pr voir une p riode de refroidissement respec wd ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage e Ne pas obstruer les orifices ou filtrer l alimentation en air du poste 33 LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s J im ASS Co e Mettre un bracelet antistatique AVANT de mani puler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PIECES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des bl
48. lying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e 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 e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding sra m FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2223
49. nal See rating label on unit and check input voltage available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 11 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size EL Jo U Welding Power Source Input Power Connections 2 Strain Relief 1 Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor IMPORTANT 5 Reed Switch Ground Current 6 Sensor Optional Input Terminal Board Connect green or green yellow grounding conductor to welding power source grounding terminal first If unit is equipped with optional ground current sensor route grounding conductor through reed switch two times and connect to grounding termi nal 6 Welding Power Source Line Terminals 7 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line terminals Close and secure access door on welding power source Disconnect Device Input Power Con nections 8 Disconnect Device switch shown in OFF position 9 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first Tools Needed 3 28 3 8 in 10 Disconnec
50. nductor 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 4 12 Placing Jumper Links A Disconnect and lockout tag out input power before installing or moving jumper links Check input voltage available at site 1 Jumper Link Label Check label only one is on unit 2 Jumper Link Move jumper links to match input voltage and label on unit Close and secure access door or go on to Section 4 13 380 VOLTS 400 VOLTS 440 VOLTS o A oo o o Alf oo o o looo ooo A o oo o A o oo o A o o o Alo o o o fc o oo A o o o looo oo o A o oo A o o Ref S 174 975 A 230 VOLTS 460 VOLTS 575 VOLTS AAAA o o AIRGAS o FAIR o offo o o off o o oAR o o o S PE a lt o o o A ARAN o o o A O o o o o o off Ref S 174 973 A E Do not overtighten jumper link nuts Tools Needed C FAO 3 8 in Ref 802 295 OM 2223 Page 19 4 13 Connecting Input Power Installation must meet all National and Local Codes have only quali fied persons make this installation A Disconnect and lockout tagout in put power before connecting input conductors from unit A Make input power connections to the welding power source first Always connect green or green yellow conductor to supply grounding terminal first and never toa line termi
51. op 24 LE add 038 887 sz STUD pribd brs 10 32 X 1 975 ura din 24 038 618 LINK jumper term bd pri 8 vous lon sand eL 010913 WASHER flat 218 ID brs 22 02 0252 sc eee em 24 THE ee a 601 8354 NUT 10 92 DIS ns ps Li edere E eee ea Mu PC 159034 HOLDER fuse MINI uui uter nn dece a ce Rn e ne Peces 1 TES 5 PNE El ied 156 065 FUSE crtg 5A 600V time delay 1 ce Epistolis iride Figure 8 4 PANEL rear w components 1 Tro PERTENECER 193 676 TERMINAL ASSY primary 3phase 1 tx dr Sunt CR4 140 750 sc SWITCH VECO 24412 ouai px Reni ew madd bb iere 1 TIC p WE ara 193 473 CONTACTOR size 3 1 2 3P 24VAC 1 TU TTT 217 136 LABEL warning electric shock 2 TT Eq E 176 254 LABEL general precautionary wordless intl CE models only 2 prob piove e eee 193 462 BRACKET contactor mount 50 Hz Models Only 2 Lc 193 462 BRACKET contactor mount 60 Hz Models Only 1 M c aT CENE ERE 103309 20 BASE xc 1 SC PES Til tos ies 218414 TRANSFORMER pwr main 230 460 575 1 HO Well ene i 218415 TRANSFORMER pwr main 380 400 440 1 E EEEE TP1 2 175405 THERMOSTAT NC Included w T1 2 ee TP4 5 168891 THERMOSTAT NC
52. ork 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 after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Head the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritatin
53. ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 Porter des lunettes de s curit crans lat raux sous le masque Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit gt W LE SOUDAGE peut causer un incen REZ die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles les pi ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger Se prot ger et prot ger les tiers de la projection d tincelles et de m tal chaud Ne pas souder un endroit o des tincelles peuvent tomber sur des substances inflammables Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es Des tincelles et des mati res en fusion peuvent fa
54. output Have Factory Authorized Service Agent check control board PC1 and hall device HD1 Check position of Remote Amperage Voltage Control switch see Section 5 1 Erratic or improper weld output Use proper size and type of weld cable see Section 4 8 Clean and tighten all weld connections Check wire feeder installation according to Owner s Manual Check position of Process selector switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 and hall device HD1 No 115 volts ac output at duplex recep tacle Remote 14 receptacle or terminal strip 1T Reset circuit breaker CB1 see Section 4 7 No 24 volts ac output at Remote 14 re ceptacle or terminal strip 1T Reset circuit breaker CB2 see Section 4 7 Fan not operating Note fan only runs when cooling is necessary Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc poor control of arc direction Reduce gas flow rate Select proper size tungsten Properly prepare tungsten Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Properly prepare tungsten Check for water in torch and repair torch if necessary See torch Owner s Manual Digital meter not workin
55. ption 195 048 Ground Current Sensor When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts 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 2223 Page 29 ICS Hardware is common and not available unless listed 802 297 Figure 8 2 Panel Front w Components Figure 8 1 Item 32 OM 2223 Page 30 Item Dia Part NO Mkgs NO Description Quantity Figure 8 2 Panel Front w Components Figure 8 1 Item 32 Sar lt Loe e EA 15936342 ELECTRONICS BOX surtir naa 1 Rade dO A POL rasa 207 035 CIRCUIT CARD ASSY control 50Hz 1 T E PGA cients 207 034 CIRCUIT CARD ASSY control 60HZ 1 TC PLG1 158720 CONNECTOR amp SOCKETS see Figure 8 3 Nm PLG3 169240 CONNECTOR amp SOCKETS 1 ral ad dtd dicts ds PLG4 148439 CONNECTOR 8 SOCKETS 1 PETE AE T E PLG5 152249 CONNECTOR 8 SOCKETS 1 RE ELA PLG16 158719 CONNECTOR 8 SOCKETS 1 M LS B3 s dose 052 964 RELAY encl 24 VDC DPDT 1 T rm CR5 006 393 RELAY encl 24VAC DPDT
56. quent de projeter du laitier e Porter des lunettes de s curit a crans lat raux agr s m me sous le masque de soudage OM 2223 Page 6 LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de 79 non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air agr LES PIECES CHAUDES peuvent cau ser des br lures graves e Ne pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e Ils doivent consulter leur m decin avant de s appro cher d un lieu o on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES endommag es peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de
57. rc 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 6 Months Batteries 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s 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 Equipmentthat 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 B
58. rer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2223 Page 33 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 7 Miller Effective January 1 2005 Equipment with a serial number preface of LF 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 writ
59. s pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS 3 1 General Precautionary Label Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Ha
60. 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 A During operation keep everybody especially children away Lr ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equ
61. ss 1635 W Spencer Street Appleton WI 54914 USA Declares that the product Di mension 1 000 1 250 conforms to the following Directives and Standards Directives Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 April 1998 Draft revision Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1 1992 Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 European Contact Danilo Fedolfi Managing Director ITW WELDING PRODUCTS S r l Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Telephone 39 02 98290 1 Fax 39 02 98290 203 dec_con1 10 95 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage i A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols C7 Means Note not safety related 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
62. t Device Line Terminals Connect input conductors L1 U L2 V C Z H0 3 8 in And L3 W to disconnect device line terminals E p 11 Overcurrent Protection Select type and size of overcurrent protec tion using Section 4 11 fused disconnect switch shown Close and secure door on line disconnect device Remove lockout tagout device and place switch in the On position Ref 800 103 C Ref 802 295 OM 2223 Page 20 Notes D Work like a Pro Pros weld and cut 4 N safely Read the ES safety rules at SAN the beginning of this manual OM 2223 Page 21 SECTION 5 OPERATION 5 1 Controls 4 1 2 A A A A EN V VOLTS A AMPS WP cv S B ARC a D 96 oo PER se FORCE PROCESS A PANEL Ko A High Temp MIN MAR Shutdown ON A Remon ade a CONTROL GOL ANVADJUST N POWER O orr 6 Dimension 1250 Nameplate 5 207 729 OM 2223 Page 22 1 Arc Force Dig Control Control increases SMAW short circuit amperage which allows the operator to use a very short arc length without sticking the electrode oet control at 0 for normal welding amper age Turn clockwise to increase short circuit amperage 2 Process Selector Switch e CV Sub Arc Mode For SAW Sub Arc applications requiring 1 16 in dia and larger welding wire e CC Mode For SMAW Stick GTAW TIG scratch start only or SAW Sub Arc applications NOTE For best results use the Positive Hig
63. ve a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arcrays 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 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label 1 2 4 OM 2223 Page 9 3 2 Input Connection Label OM 2223 Page 10 S 179 290 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection points and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring and exposed weld terminals can kill

Miller Electric 1000 Welder User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents