OM-221 677C
2006−07
Effective with serial number 222 842
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Description
Arc Welding Power Source
Blu-Fab 3500
and 4500 Series
OWNER’S MANUAL
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS−READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Typical MIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Remote 14 Receptacle RC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting Welding Gun And Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Installing Wire Guide And Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-2. Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-3. Run-In Control and Burnback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 7 - ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 8 - PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
Blu-Fab 3500/4500
conforms to the following Directives and Standards:
Directives
Electromagnetic Compatibility Directives: 89/336/EEC
Low Voltage: 73/23/EEC
Machinery Directives: 98/37/EEC
And their amendments 91/368/EEC, 92/31/EEC, 93/44/EEC, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995
Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1989
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_stat_Milan_6/05
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
eng_som_woPPS_3/05
Y
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
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.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y
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
Safety Standards.
D
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D
D
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
During operation, keep everybody, especially children, away.
D
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
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
groundedequipment is a hazard.
D
D
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if 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.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
D
D
FUMES AND GASES can be hazardous.
D
Additionalsafety 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
semiautomaticDC 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!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
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.
D
D
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated 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.
D
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).
D
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
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
groundedreceptacle outlet.
D
D
D
D
When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
OM-221 677 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
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.
D
Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
D
D
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
MAGNETIC FIELDS can affect pacemakers.
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
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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.
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
NOISE can damage hearing.
D
D
D
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
damagehearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
Wear approved ear protection if noise level is
high.
D
D
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.
CYLINDERS can explode if damaged.
D
D
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).
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.
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.
D
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
D
D
Do not use welder to thaw frozen pipes.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D
D
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.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
D
D
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.
D
OM-221 677 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
READ INSTRUCTIONS.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
D
Read Owner’s Manual before using or servic-
ing unit.
D
Do not install unit near flammables.
D
Use only genuine Miller/Hobart replacement
parts.
D
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.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
H.F. RADIATION can cause interference.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
If notified by the FCC about interference, stop using the
equipmentat once.
D
D
Have the installation regularly checked and maintained.
D
Do not block or filter airflow to unit.
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.
STATIC (ESD) can damage PC boards.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can cause injury.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D
Do not press gun trigger until instructed to do
so.
D
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
MOVING PARTS can cause injury.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
D
D
For Diesel Engines:
Y
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-221 677 Page 3
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1-4. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
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).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
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).
NationalElectrical 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).
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).
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).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables 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.
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
committee’s 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.
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 Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-221 677 Page 4
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SECTION 2 − DEFINITIONS
Warning! Watch Out! There are possible
hazards as shown by the symbols.
2.1 Keep your head out of the fumes.
4
Arc rays can burn eyes and injure
skin.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
1
Electric shock can kill.
4.1 Wear hat and safety glasses. Use
ear protection and button shirt collar.
Use welding helmet with correct
shade of filter. Wear complete body
protection.
2.3 Use ventilating fan to remove fumes.
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
3
Welding sparks can cause explosion
or fire.
1.2 Protect yourself from electric shock
by insulating yourself from work and
ground.
3.1 Keep flammables away from welding.
Do not weld near flammables.
5
Become trained and read the
instructions before working on the
machine or welding.
3.2 Welding sparks can cause fires.
Have a fire extinguisher nearby, and
have a watchperson ready to use it.
1.3 Disconnect input plug or power
before working on machine.
6
Do not remove or paint over (cover)
the label.
2
Breathing welding fumes can be
hazardous to your health.
3.3 Do not weld on drums or any closed
containers.
Do not discard this product 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-221 677 Page 5
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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.
1
Consult rating label for input
power requirements, and
check power available at the
job site − they must match.
2
3
4
5
Read Owner’s Manual and
inside labels for connection
points and procedures.
Move jumper links as shown
on inside label to match
voltage at job site.
Having a loop of extra length,
connect grounding conductor
first.
Connect line input conductors
as shown on inside label −
double-check all connections,
jumper link positions, and
input voltage before applying
power.
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1
2
Moving parts, such as fans,
can cut fingers and hands and
cause injury. Keep away from
moving parts.
S-176 106
1
1
2
3
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling unit can cause injury.
Do not move or operate unit
where it could tip.
Cylinders can expolde if
damaged. Protect
compressed gas cylinders
from excessive heat,
mechanical shock, slag, open
flames, sparks, and arcs.
2
3
OM-221 677 Page 6
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SECTION 3 − INTRODUCTION
3-1. Included with Your Unit
1
1
2
3
4
Power Source
Power Cord (4m)
Work Cable and Clamp (4m)
Running Gear
2
3
4
3-2. Specifications
Rated Output
at 45% Duty
Cycle
Welding
Range
Max. OVC
Input Rating
KVA
Dimensions
Net Weight
Blu-Fab 3500
Blu-Fab 4500
350 A 32 V
16-32
38
400−18A
11.8 KVA
Length: 1040mm
Height: 760mm
Width: 435mm
146 kg
450 A 37 V
14-37
47
400-27A
17.7 KVA
Length: 1040mm
Height: 760mm
Width: 435mm
156 kg
3-3. Duty Cycle Chart
800
700
600
500
Blu-Fab 3500: 45% Duty Cycle at 32V, 350A
Blu-Fab 4500: 45% Duty Cycle at 37V, 450A
Duty cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
400
300
Y
Exceeding duty cycle can
damage unit and void
warranty.
450
350
4.5 Minutes
Welding
5.5 Minutes
Resting
200
20 25 30 35 40 50 60 708090100
% DUTY CYCLE
3-4. Volt-Ampere Curves
Blu-Fab 3500
Blu-Fab 4500
OM-221 677 Page 7
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SECTION 4 − INSTALLATION
4-1. Selecting a Location
Position unit so air can circulate.
500 mm
500 mm
500 mm
4-2. Typical MIG Connections
5
1
2
3
4
Power source
Work clamp (connect to receptacle as shown)
Cylinder (chain to running gear)
Cylinder valve
4
6
Open valve slightly so gas flow blows dirt from valve.
Close valve.
5
Regulator/Flow gauge
Install so face is vertical.
6
7
8
9
Flow adjust
Gas supply line
Wire feeder
MIG torch
7
3
8
1
9
2
OM-221 677 Page 8
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4-3. Electrical Service Guide
Blu-Fab 3500
Blu-Fab 4500
Input Voltage
400
21A
21A
400
30A
30A
Input amperes at rated output
Fuse or circuit breaker rating (max. rec)
Input conductor size
2
2
6 mm
6 mm
2
2
Grounding conductor size**
6 mm
6 mm
** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations.
4-4. Connecting Input Power
GND/PE
Y
Y
Have only qualified persons
make this installation.
Special installation may be
required where gasoline or
volatile liquids are present −
consult national or local reg-
ulations.
GND/PE
Connect first.
L3
L1
L2
Tools Needed:
4-5. Remote 14 Receptacle RC1
Socket
Information
A
B
I
24 volts ac.
OUTPUT
24 VOLTS AC
115 VOLTS AC
(CONTACTOR)
Contact closure to A completes 24 volts ac contactor control circuit.
115 volts AC, protected by fuse.
OUTPUT
K
Chassis common.
GND
G
Circuit common for 24 and 115 volts ac circuits.
OM-221 677 Page 9
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4-6. Connecting Welding Gun And Weld Cable
1
2
3
Gun Securing Knob
Gun Block
Gun Outlet Wire Guide
Loosen knob, insert gun into block.
Position outlet wire guide as close
as possible to drive rolls without
touching. Tighten knob.
1
4
Gun Trigger Plug
5
6
7
Gun Trigger Receptacle
Weld Cable Terminal
3
2
Euro Torch
Weld Cable From Welding
Power Source
US Torch
5
7
4
6
4-7. Installing Wire Guide And Drive Roll
1
Inlet Wire Guide
1−2
2
Intermediate Wire Guide
Install and secure inlet wire guide,
and intermediate wire guide.
3
Drive Roll
Install drive rolls and turn drive roll
nut one click.
During maintenance intervals,
remove drive rolls, and clean
grooves using a wire brush. Check
general condition of drive rolls.
3
Correct Alignment
Aligning Wire Guide And Drive
Rolls:
View is from top of drive rolls
looking down with pressure assem-
bly open.
Turn screw in or out until drive roll
groove lines up with wire guide.
Close pressure roll assembly.
Repeat for remaining drive rolls un-
til all drive rolls line up with wire
guides as shown.
Incorrect Alignment
Tools Needed:
3/8 in
802 310-A
OM-221 677 Page 10
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SECTION 5 − OPERATION
5-1. Controls
1
Power Switch
1
2
3
4
5
6
The power switch is a selector knob
which permits selection of operation
on either of the two available ranges
(I and II) and the center position is off.
2
Indicator Lamp
This lights up when the power switch
is placed in the ON position.
3
Protection Fuse
Fuse F protects the control circuit.
Should it become necesary to re-
place any fuse in the welding power
source, be sure to substitute with one
of the same size and rating.
4
Use this control to adjust weld
voltage 10 position switch. 20
weld setting, 10 high range (I),
10 low range (II).
5
High Temperature Shutdown
Light
7
8
This lights up when unit overheats
and shuts down.
6
Voltage/Amperage Meter.
Use toggle switch to select voltage or
amperage.
7
Low Inductance Negative
Output Terminal
Connect work lead here for most
“short-arc” applications.
8
High Inductance Negative
Terminal
Front Panel
Connect work lead here for stainless
steel and spray arc conditions.
9
10
11
9
115 AC Receptacle (optional)
Located on the rear panel is a recep-
tacle which provides power to the gas
heater, when welding with CO
2
shieldinggas and for the cooling sys-
tem.
10 Wire Feeder Power Cable
Receptacle
Located on the rear panel is a recep-
tacle used to supply operating power
to the wire feed unit.
115 VAC
11 Positive Out Terminal
Back Panel
OM-221 677 Page 11
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5-2. Panel Controls
1
2
3
4
5
6
7
8
9
Voltage Control
Purge Control
Jog
1
2
3
4
5
2T−4T Switch
Power ON-OFF
Torch Connection
Circuit Breaker
Gas In Connector
Control Cable Connection
7
8
10 Weld Cable Connection
9
10
6
5-3. Run-In Control and Burnback Control
Run-In Control
Use control to set wire feed speed
before arc initiation
6
4
After arc initiation, wire feed speed
is controlled by the wire feed speed
control on the front control panel.
2
8
Burnback Control
Control adjusts the time welding
wire is energized after wire feed
stops.
10
6
4
2
8
10
t
OM-221 677 Page 12
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SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
Y
Disconnectpower before maintaining.
. Maintain more often during severe conditions.
3 Months
Replace unreadable labels.
Clean and tighten weld terminals.
Repair or replace cracked weld
cable.
Repair or replace cracked gas
hose.
Replace o-ring in Electrode/Gas
Output receptacle if cracked.
6 Months
Blow out or vacuum inside.
OR
6-2. Troubleshooting
Trouble
Remedy
Check and replace if necessary.
No weld output; fan does not run.
No weld output; fan on.
Tighten wire feeder connection to Remote 14 receptacle.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Fan not operating; weld output
available.
OM-221 677 Page 13
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Notes
OM-221 677 Page 14
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SECTION 7 - ELECTRICAL DIAGRAM
A - A V L D I G I T
3 T L
2 S L
1 R L
3 T L
2 S L
1 R L
P O S I Z I O N I
956142300_9−10−04
OM-221 677 Page 15
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Item
No.
Dia.
Mkgs.
Part
No.
Description
BF3500 BF4500
8-1. Main Assembly
. . . 1 . . . . . . . . . . . 116121119 . . Wrapper, Top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 2 . . . . . . . . . . . 156002044 . . Handle Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 3 . . . . . . . . . . . 056072075 . . Power On Indicator light assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 4 . . . . . . . . . . . 056072076 . . Knob Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 5 . . . . . . . . . . . 000046432 . . Fuse Holder Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 6 . . . . . . . . . . . 056092039 . . Fuse, Aux Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 7 . . . . . . . . . . . 056072076 . . Over Temp Indicator light assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 9 . . . . . . . . . . . 116118150 . . Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 10 . . . . . . . . . . . 056076152 . . Dinze Output socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3
. . . 10 . . . . . . . . . . . 056076169 . . Dinze Output socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3
. . . 11 . . . . . . . . . . . 056067169 . . *Switch Volt/Ammeter (opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 12 . . . . . . . . . . . 116005081 . . Mounting Bracket, Rectifier Assy . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 13 . . . . . . . . . . . 056159008 . . Thermal Cutout switch PCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 14 . . . . . . . . . . . 056050058 . . Rectifier, Main welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . 056050017 . . Rectifier, Main welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . 056059257 . . Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . 056059262 . . Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 028021447 . . Main Transformer 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 028021448 . . Main Transformer 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . 027015542 . . Coil, Primary/Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . 027015541 . . Coil, Primary/Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . 156031040 . . Mounting Bracket, Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 19 . . . . . . . . . . . 028038040 . . Stabilizer Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . 028038041 . . Stabilizer Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . 156006030 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 21 . . . . . . . . . . . 057079032 . . Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . 057079033 . . Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . 057014030 . . Primary Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . . . . . . . . . . . . . . . 057024004 . . Capcitor C1,C2 & C3 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3
. . . . . . . . . . . . . . . . . 056059189 . . Resistor R1,R2 & R3 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3
. . . 23 . . . . . . . . . . . 356078032 . . Fan Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 24 . . . . . . . . . . . 116118151 . . Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 25 . . . . . . . . . . . 000173283 . . Fan Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 26 . . . . . . . . . . . 056076170 . . Receptacle, 14 Pin Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 27 . . . . . . . . . . . 116122277 . . Wrapper, Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 27 . . . . . . . . . . . 116122278 . . Wrapper, Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 28 . . . . . . . . . . . 000124274 . . Bracket, Mounting, Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 29 . . . . . . . . . . . 056126072 . . Fan Motor 230VAC 50/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 30 . . . . . . . . . . . 056067196 . . Switch, 10 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . 056067205 . . Switch, 10 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . 056067203 . . Switch, 3 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . 067067204 . . Switch, 3 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . 157095014 . . PCB, Digital Volt/Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . 058021042 . . Transformer, Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 34 . . . . . . . . . . . 056091041 . . Clamp, Cable strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 35 . . . . . . . . . . . 116122280 . . *Front base plate cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 36 . . . . . . . . . . . 000006393 . . Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, XFM mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . 4
. . . 38 . . . . . . . . . . . 156085088 . . “A” Frame upright bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
. . . 39 . . . . . . . . . . . 157029012 . . “A” Frame cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 40 . . . . . . . . . . . 316029695 . . Name plate, Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . 316029697 . . Name plate, Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . 056054065 . . *Castor, Front, swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
. . . 42 . . . . . . . . . . . 116085123 . . *Bracket, mounting, front castor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 43 . . . . . . . . . . . 056054064 . . *Wheel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
. . . 44 . . . . . . . . . . . 057029005 . . *Axle assy, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 45 . . . . . . . . . . . 156009067 . . *Washer, Plain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
. . . 46 . . . . . . . . . . . 156087017 . . *Pin, Split type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
. . . 47 . . . . . . . . . . . 117029005 . . *Bottle Rack Assy, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1
. . . 48 . . . . . . . . . . . 156085087 . . “A” Frame Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
* Optional, certain markets
OM-221 677 Page 17
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Item
No.
Dia.
Mkgs.
Part
No.
Qty
Description
. . . 1 . . . . . . . . . . . 000058427 . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . 156032128 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . 156018033 . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . 156009079 . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . 156032064 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . 156009075 . . Washer, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . 000186435 . . Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . 000186436 . . Washer, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . 156005108 . . Support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . 056076216 . . Dinze Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . 056076192 . . Receptacle, 14 pin male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . 056061042 . . Gas Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . 000083432 . . CB1 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . 116118168 . . Rear Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 117060014 . . Plate, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . 000151187 . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . 116122319 . . Side Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . 156034004 . . Hinge, Polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . 000208015 . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . 156121022 . . Cover, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . 000204326 . . Compartment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . 057084110 . . Circuit Card, control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . 056093022 . . Switch, gas purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . 056093022 . . Switch, wire jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . 056067169 . . Switch, 2T 4T trigger latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . 056067194 . . Switch, power on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . 316029696 . . Nameplate, upper polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . 000207076 . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . *756005024 . . Flange, euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . 316029694 . . Nameplate, lower polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . 116118167 . . Front Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . 056059182 . . Potentiometer, wire speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . 156005097 . . Motor Support, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . 056059277 . . Potentiometer, 10.Kohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . +178−937A . . Label, electric shock and pinch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . +116006130 . . Base, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . *057052032 . . Euro torch adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . Fig 8-3 . . Wire Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . Optional . . US torch plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . +S178−936 . . Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . 656110012 . . Foot, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . 027112275 . . Weld cable, w/lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . . . . . . . Grommet, blanking plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . 057028075 . . PCB Run-In Control and Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . 956142486 . . Label, Run-In and Burnback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Optional, certain markets
OM-221 677 Page 19
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. Hardware is common and
not available unless listed
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19
18
17
16
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15
2
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3
4
4
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5
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9
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9/13/04
Figure 8-3. Wire Drive Assembly (All Models)
Item
No.
Dia.
Mkgs.
Part
No.
Qty
Description
. . . 1 . . . . . . . . . . . 057010052 . . Drive Motor, 24 VDC, 60w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 187 325 . . Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . Bolt, Power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 602 213 . . Washer, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . 656005029 . . Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 206219 . . Housing, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 124778 . . Knob, T Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 604 673 . . Screw, hex c/sunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 173 618 . . Drive Gear, central . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 602 239 . . Washer, central drive gear/shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 174 609 . . Screw, central drive gear/shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 602 009 . . Screw, soc head hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 601 872 . . Nut, power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 602 213 . . Washer, plain, power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 010 224 . . Pin, tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 166971 . . Lever, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 089562 . . Fastener, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . . . . 196896 . . Cup, tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 196897 . . Spring, tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 196895 . . Knob, adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-221 677 Page 20
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Effective January 1, 2006
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, ITW Welding Products Italy S.r.l., 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.
*
*
*
*
*
*
APT 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:
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.
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
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.
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 European
distributor or eighteen months after the equipment is sent to
an International distributor.
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.
1. 5 Years Parts − 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
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.
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
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 ITW Welding
Products Group Europe, 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.
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 2 year − Parts and Labor (Panther only)
Hydramate 1&2 Water Cooling Unit
4. 1 year − Parts and Labor unless specified
*
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.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DC 253 & 403 Rectifier (April 06>)
Migmatic 171 (April 06>)
Motor Driven Guns (w/exception of Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
IHPS Power Sources and Coolers
Water Coolant Systems (non−integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud power sources and Arc Stud guns
Running Gear/Trailers
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
Plasma Cutting Torches (except APT
Models)
&
SAF
*
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.)
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.
5
6 Months — Batteries
6. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction heating coils and blankets
milan_warr 1/06
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
Country
Zip/Postal Code
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
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Products Italy S.r.l.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
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
© 2006 Miller Electric Mfg. Co. 1/06
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