OM-230 009F
2008−01
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
PipePro Dual
DX Feeder
File: MIG (GMAW)
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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. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Typical Connection Diagram For MIG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Typical Connection Diagram For TIG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Typical Connection Diagram For Stick Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-7. Setting Internal DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-8. Display Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-3. Left/Right Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-4. Jog/Purge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-5. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-6. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-7. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-8. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-9. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-10. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-11. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-12. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-13. Remote-14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-1. Optional Dual Schedule Switch Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
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Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
. Indicates special instructions.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
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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.
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
follow all Safety Standards.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and
repair this unit.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
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Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.
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.
ELECTRIC SHOCK can kill.
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Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
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
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
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.
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Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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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.
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!
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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.
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Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
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Do not connect more than one electrode or work cable to any
single weld output terminal.
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SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
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Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
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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).
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To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
OM-230 009 Page 1
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Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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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.
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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.
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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.
FLYING METAL or DIRT can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
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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.
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Wear approved safety glasses with side
shields even under your welding helmet.
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.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
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.
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Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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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).
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ImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
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Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
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Wear approved ear protection if noise level is
high.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
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.
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.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
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Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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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.
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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).
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Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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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.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
OM-230 009 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
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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 reconnecting input power.
FALLING UNIT can cause injury.
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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.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
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Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
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Do not block or filter airflow to unit.
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FLYING SPARKS can cause injury.
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The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
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Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
If notified by the FCC about interference, stop using the
equipmentat once.
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Have the installation regularly checked and maintained.
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Sparks can cause fires — keep flammables away.
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.
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Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
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Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
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Be sure all equipment in the welding area is
electromagneticallycompatible.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
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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 elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
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Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
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OM-230 009 Page 3
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1-4. California Proposition 65 Warnings
For Gasoline Engines:
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 & Safety Code Section 25249.5 et seq.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
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
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. 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).
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044,website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900,website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
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).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
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-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 5060 Mississauga,
1-6. 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, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
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 Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-230 009 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2007−04
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
. Indique des instructions spécifiques.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re-
commandée.En outre, ne pas travailler seul !
Les symboles représentés ci-dessous sont utilisés dans ce ma-
nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec-
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentationselon la norme OSHA 29 CFR 1910.147 (voir nor-
mes de sécurité).
Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
nationales,provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D
D
Seul un personnel qualifié est autorisé à installer, faire fonc-
tionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes,notamment les enfants de l’appareil.
D
D
En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
D
D
Ne pas toucher aux pièces électriques sous tension.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D
D
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide dou-
blée.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil
conformémentà ce manuel.
D
D
Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D
D
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
D
D’autres consignes de sécurité sont nécessaires dans les condi-
tions suivantes : risques électriques dans un environnement
humideou si l’on porte des vêtements mouillés ; sur des structures
métalliquestelles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
D
Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
D
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-230 009 Page 5
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Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a
coupé l’alimentation.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
D
Arrêter les convertisseurs, débrancher le courant électrique et
déchargerles condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliquespeut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D
Ne pas toucher à mains nues les parties
chaudes.
D
Prévoir une période de refroidissement avant de
travailler à l’équipement.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusementavec des protections homologués.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
D
D
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereux pour votre santé.
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
mes de sécurité).
D
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais-
seurs.
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
quant des risques d’électrocution, d’étincelles et d’incendie.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtementset tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
D
D
D
D
D
D
Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D
Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliquesvolantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D
Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
OM-230 009 Page 6
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D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D
Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D
Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
d’air homologué.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
D
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de sou-
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécu-
rité.
dage, les manipuler avec précaution.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Porter un écran facial pour protéger le visage et
les yeux.
D
Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D
Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv-
re est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Prévoir une période de refroidissement ; re-
specter le cycle opératoire nominal.
D
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D
Ne pas obstruer les passages d’air du poste.
OM-230 009 Page 7
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LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Maintenirfermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec-
tion.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D
L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et l’é-
quipement commandé par ordinateur tel que
les robots.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
D
Veiller à ce que tout l’équipement de la zone de soudage soit
compatibleélectromagnétiquement.
D
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentairestelles que le déplacement du poste, l’utilisation de câ-
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
D
D
D
N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
D
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
2-4. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmesde procréation. Se laver les mains après manipu-
lation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
OM-230 009 Page 8
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2-5. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900,site Internet : www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone
1-877-413-5184,site Internet : www.global.ihs.com).
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-
tilly, VA 20151 (téléphone
www.cganet.com).
:
703-788-2700, site Internet
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
CanadianStandards Association, 5060 Mississauga, Ontario, Canada
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa-
miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiqueset champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-230 009 Page 9
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OM-230 009 Page 10
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SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
A
B
C
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1
Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1
2
1.1
2.1
3.1
4.1
1.2
1.3
1.3 Disconnect input plug or
power before working on
machine.
2
Breathing welding fumes can
be hazardous to your health.
2.2
2.3
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3
4
5
3.2
3.3
3
Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
+ + +
3.3 Do not weld on drums or any
closed containers.
4
Arc rays can burn eyes and
injure skin.
6
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.
+
S-178 936
5
Become trained and read the
instructions before working on
the machine or welding.
6
Do not remove or paint over
(cover) the label.
OM-230 009 Page 11
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3-2. Symbols And Definitions
. Some symbols are found only on CE products.
Amperes
Volts
Alternating Current
Program
Duty Cycle
Wire Feed
A
IP
V
Hz
X
Degree Of
Protection
Hertz
Jog
Output
Trigger
Line Connection
Trigger Hold Off
Set Up
Sequence
Trigger Hold On
Purge
Time
Press To Set
Preflow Time
Start
Crater
Postflow Time
Rated Current
Read Instructions
Load Voltage
Increase
Primary Current
Dual Schedule
I1
I2
U2
A
B
Primary Voltage
U1
SECTION 4 − INTRODUCTION
4-1. Specifications
Welding
Circuit
Rating
Type of Input
Power
Welding Power
Source Type
Wire Feed Speed
Range
Wire Diameter
Range
IP
Rating
Overall
Dimensions
Weight
40 Volts DC
10 Amperes
PipePro 450 RFC with
14-Pin And Contactor
Control
50 To 780 ipm
(1.3 To 19.8 mpm)
.023 To 1/8 in
100 Volts,
750
Amperes,
100% Duty
Cycle
IP 21
Length: 35 in
(889 mm)
87 lb
(39.5 kg)
(0.6 To 3.2 mm)
Width: 12-1/2 in
(318 mm)
Max Spool
Weight: 60 lb
(27 kg)
Height: 14 in
(356 mm)
OM-230 009 Page 12
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SECTION 5 − INSTALLATION
5-1. Typical Connection Diagram For MIG Equipment
1
9
10
3
2
4
8
5
7
11
804 665-C
6
2
3
4
5
6
7
Negative Volt Sense Cable
Positive (+) Weld Cable
Negative (−) Weld Cable
Workpiece
8
9
Gas Hose
!
Do not mount feeder on top of pow-
er source.
Gas Cylinder
Do not put feeder where welding
wire hits cylinder.
10 14-Pin Feeder Control Cable
11 Remote Switch To MIG
Do not move or operate equipment
when it could tip.
Welding Power Source
Welding Gun
. Maximum cable length not to exceed
1
Wire Feeder
150 feet.
OM-230 009 Page 13
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5-2. Typical Connection Diagram For TIG Equipment
. The illustration shows remote control connected through the wirefeeder.
The wirefeeder is not connected to the power source output..
1
2
12
3
5
4
6
10
11
7
9
804 779-A
8
2
Gas Cylinder
Gas Hose
Positive (+) Weld Cable
Negative (−) Weld Cable
Torch
9
Wire Feeder
Do not mount feeder on top of pow-
er source.
3
4
5
6
7
8
10 14-Pin Feeder Control Cable
11 Remote Switch To STICK/TIG
12 Volt Sense Receptacle
(Cable Disconnected)
Do not put feeder where welding
wire hits cylinder.
Do not move or operate equipment
when it could tip.
Welding Power Source
Workpiece
Foot Control
. Maximum cable length not to exceed
1
150 feet.
OM-230 009 Page 14
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5-3. Typical Connection Diagram For Stick Equipment
. The illustration shows remote control connected through the wirefeeder.
The wirefeeder is not connected to the power source output..
1
2
3
4
8
5
9
7
804 780-A
6
1
2
3
4
5
Welding Power Source
6
7
8
9
Hand Control
Do not mount feeder on top of pow-
er source.
Wire Feeder
14-Pin Feeder Control Cable
Remote Switch To STICK/TIG
Negative (−) Weld Cable
Positive (+) Weld Cable
Workpiece
Do not put feeder where welding
wire hits cylinder.
. Maximum cable length not to exceed
Do not move or operate equipment
when it could tip.
Electrode Holder
150 feet.
OM-230 009 Page 15
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5-4. Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable
Shielding Gas Valve Fittings
Requires fitting with 5/8-18 right-
hand threads. Connect customer-
supplied gas hose.
3
4
5
6
7
Weld Cable Terminal
Jumper Weld Cable
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
8
Rating Label Location
To rotate the drive assembly, loos-
en drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
8
2
1
3
4
5
5
4
6
7
Tools Needed:
9/16, 5/8 in
3/16 in
Ref. 804 766-A / 803 067 / 802 825-A
OM-230 009 Page 16
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5-5. 14-Pin Plug Information
Pin*
Pin Information
A
G
B
40 volts dc with respect to socket G.
Circuit common for 40 volts dc circuit.
Contact closure to K completes contactor control circuit.
Contact closure to B completes contactor control circuit.
K
J
A
C
D
E
H
F
+10 volts dc input from power source to wire feeder with respect to socket D.
Remote volt control circuit common.
K
I
B
C
L
H
N
0 to +10 volts dc remote volt/trim signal from wire feeder to power source with respect to socket D.
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
M
E
G
D
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
M
N
L
0 to +10 volts dc remote WFS signal from wire feeder to power source with respect to socket N.
Remote WFS control circuit common.
Electrode sense.
I
Remote Program Select A
Remote Program Select B
J
Notes
OM-230 009 Page 17
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5-6. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spools. Adjust tension nuts so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Indicator
Pressure
Adjust
Rear
Scale
Pressure
Adjust
Front
Rolls
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Tools Needed:
Drive Rolls
3/16, 5/64 in
15/16, 3/8 in
Back Of Gun
End Of Liner
. For best wire feeding performance, be . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
sure that the outlet cable has the proper
size liner for the welding wire size being
used. Also, when the gun is installed, the
liner extending from the back of the gun
should be as close to the drive rolls as
possible, without touching.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If con-
tact tip is completely blocked, wire should
slip at the feeder (see pressure adjust-
ment above).Cut wire off. Close cover.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 804 743-A
OM-230 009 Page 18
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5-7. Setting Internal DIP Switches
Remove wrapper.
Left Side Motor
Control Board
PC101
1
DIP Switch S1 On Motor
Board PC1
w Setting Current Detect
Override (S1-1)
Current detect override is used to
disable run-in when a welding pow-
er source is used that doesn’t pro-
vide current feedback through the
14-pin receptacle.
Right Side Motor
Control Board PC1
Install wrapper when finished.
P1
. This illustration shows
1
the factory setting of S1.
. In the DIP switch S1 illustrations,
the elevated slider on each switch
is shown in white. For example,
the switches above are all in the
Off position.
. When DIP switch positions are changed, the unit must be
turned Off and then On again in order for the new settings
to be active. DIP switches are only read on power up.
Tools Needed:
1/4 in
Position Settings And Results For DIP Switch S1 On PC1 And PC101
Current Detect Override (OFF)
(Factory Default)
Automatic Run-In (ON)
Current Detect Override (ON)
Automatic Run-In (OFF)
(Factory Default)
S1-1 And S1-2
S1-1 And S1-2
S1-1 And S1-2
S1-1 And S1-2
Off = Run-In speed is set using
potentiometer P1 located on Motor
Board PC1.
Off = Current must be detected
from power sources that provide
current feedback through the
14-pin receptacle to go from run-in
to welding condition. Run-in is
active.
On = Run-In speed is
approximately 1/2 weld wire
feed speed.
On = Current detect over-
ride. For welding power
sources that don’t provide
current feedback through
the 14-pin receptacle. Run-
in is inactive.
804 804-A / Ref. 802 944
OM-230 009 Page 19
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5-8. Display Board DIP Switch Settings
Remove wrapper.
DIP Switch S1 And S4
1
. DIP switches S1 and S4 should remain in
the factory default settings.
1
Install wrapper when finished.
Factory Set Default Settings
For DIP Switches S1 And S4
O
N
1
2
3
4
5
6
7
8
. In the DIP switch S1and S4 il-
lustration, the elevated slider on
each switch is shown in white. For
example, the switches above are
all in the Off position.
Tools Needed:
1/4 in
804 666-B / 803 063
OM-230 009 Page 20
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SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this wire feeder:
General Terms:
Cold Wire Jog
Sequence
Feeding wire without contactor or gas valve being energized.
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
A group of sequences that make up a weld cycle.
Weld Program
6-2. Power Switch
1
Power Switch
1
804 667-B
6-3. Left/Right Select Switch
1
Left/Right Select Switch
Pressing the Left/Right Select
switch allows the operator to
choose which side of the units’ con-
trols will operate.
. Depressing the Left or Right
Gun Trigger also allows the
operator to enable the con-
trols on that side of the unit.
1
804 668-B
OM-230 009 Page 21
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6-4. Jog/Purge Switch
1
2
3
Jog/Purge Switch
Gun Trigger Receptacle
Adjust Control
Pressing the Jog/Purge switch
allows the operator to jog wire
without energizing the weld pow-
er or gas valve circuit.
• Jog speed can be adjusted by
the Adjust control when the
unit is jogging wire. The unit
displays jog speed when the
unit is being jogged.
• Pressing the Jog/Purge button
also allows the operator to
purge gas lines before welding
and to preset gas pressure at
the regulator.
3
2
1
804 668-B
6-5. Front Panel Controls
See
Section
See
Section
Program
See
Section
V/Trim Time (sec)
Wire Speed
Amps
Start
Dual Schedule
Trigger Hold
Crater
Pre/Postflow
Sequence
Adjust
Setup
See
Section
See
Section
See
Section
OM-230 009 Page 22
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6-6. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
Program Push Button
Press button to activate program
select feature. To change the pro-
gram number, press the Program
push button and rotate the Adjust
control.
1
2
3
Program Push Button LED
The LED lights to indicate the Pro-
gram push button is active.
Program
3
6-7. Upper Display
3
2
1
4
V/Trim
Time (sec)
5
1
Upper Display
can be changed by the Adjust control.
time is the active parameter in the upper dis-
play. At idle, the upper display toggles be-
tween showing weld voltage/trim or weld
time, with subsequent presses of the upper
display push button.
The upper display shows voltage/trim or time.
The unit displays both preset and actual arc
voltage. When the unit is in a welding state, ac-
tual arc voltage is displayed. The upper dis-
play shows welding sequence time when the
Time LED is illuminated.
4
5
Volts/Trim LED
Time LED
The LEDs below the display illuminate to indi-
cate which value is being shown.
• The unit defaults to displaying welding volt-
age/trim when a welding sequence display
mode is first entered.
At any time while welding, the unit permits the
adjustment of the weld sequence voltage/trim
while continuing to display actual arc voltage.
2
Upper Display Push Button
Press and hold button to adjust or display weld
time. Release button to display voltage/trim.
• If the weld sequence has a time set (as in
spot time) and the trigger is held, after the
weld program is completed, ERR TRG 1 will
be displayed to indicate the weld program is
complete. Release trigger to clear error.
• If the unit is displaying a welding sequence
that can be timed, the welding time display
mode is entered by pressing the upper dis-
play push button repeatedly until welding
3
Upper Display Push Button LED
The upper display push button LED illumi-
nates to indicate that information displayed
OM-230 009 Page 23
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6-8. Lower Display
3
2
1
4
Wire Speed
Amps
5
1
Lower Display
cate which value is being shown.
• Adjustingwire speed while in a welding state
will modify the weld segment of the weld pro-
gram. Wire speed for other segments of the
weld program can only be modified via the
Sequence menu.
The lower display shows wire speed or
amperage.
2
Press button to choose between wire speed or
amperagefunctions.
3
The lower display push button LED illuminates
to indicate that wire feed speed can be ad-
justed with the Adjust control.
4
5
• At idle, the wire speed for the active welding
sequence may be adjusted or the amperage
of the previous weld may be displayed.
Lower Display Push Button
• When the unit is displaying amperage, the
Amps LED illuminates. While in a welding
state, the actual weld current is shown.
While idle, the amperage at the end of the
previous welding state is shown.
Lower Display Push Button LED
• If the unit is in a welding state that does not
involve feeding wire, such as pre−flow or
post−flow, the unit displays the weld se-
quence wire speed; otherwise, the wire
speed of the active sequence segment of the
weld program (run−in, start, weld, crater,
etc.), is displayed.
Wire Speed LED
Amps LED
• Amperage values of less than 5 Amps are
displayed as “−−−−”.
The LEDs below the display illuminate to indi-
6-9. Setup Push Button
3
4
Trigger Hold
2
Dual Schedule
1
Setup
1
Setup Push Button
tus On/Off. Use the Adjust control to change • When the Setup button is pressed a second
the trigger hold status or press the lower dis-
play push button. If trigger hold is turned On,
the trigger hold LED illuminates and stays
On.
time, the dual schedule LED flashes. In this
mode the upper display indicates DUAL and
the lower display indicates dual schedule
status On/Off. Use the Adjust control to
change the dual schedule status if desired.
Press button to choose between trigger hold
or dual schedule functions.
2
3
4
Setup Push Button LED
Trigger Hold LED
• When trigger hold is On, the user must
press and hold the trigger for a predefined • Pressing the Setup button again exits the
Dual Schedule LED
amountof time (the trigger hold delay time−
ger hold function to be active. To shut off the
weld when trigger hold is On, the user must
press and release the trigger.
Setup mode. The dual schedule LED stops
flashingto indicate the dual schedule status
is Off, or remains on if dual schedule was
enabled.
• When the Setup button is pressed, the Set-
up push button LED flashes and the Trigger
Hold LED flashes.
• Trigger hold is a per program setting.
• While in the Setup mode, if the trigger is acti-
vated, Setup mode is terminated.
• If a weld time is programmed, trigger hold is
disabled.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
• Dual schedule and trigger select cannot be
Trigger Program Select.
the upper display indicates HOLD and the • Dual Schedule is a per program pair setting
lower display indicates the trigger hold sta-
(1,2) (3,4) (5,6) (7,8).
OM-230 009 Page 24
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6-10. Adjust Control
1
Adjust Control
The Adjust control is used to change
various parameters.
1
Adjust
6-11. Sequence Push Button
1
2
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
Start
3
Crater
Weld
Time
Start
Time
Pre/Postflow
Crater
Time
2
1
Preflow
Time
Postflow
Time
Welding Sequence Diagram
Sequence
the weld display mode is activated.
• When the Sequence push button is pressed
a third time, the Preflow/Postflow sequence
LED flashes. The Sequence push button
LED remains flashing. In the Preflow display
mode the upper display shows the preflow
time and the lower display indicates the ab-
breviation PRE, to inform the operator that
preflow time is displayed. If the upper dis-
play push button is pressed, the Adjust con-
trol can be used to adjust preflow.
. For more information on Setting
If zero time is programmed for a timed se-
quence except for Weld, that sequence will
be skipped.
• The Sequence push button allows the
selection of welding sequences. Five weld-
ing sequences are available. The default
sequence is the Weld sequence. The Weld
sequence is active on power up. Three
welding sequence LEDs are located above
the Sequence push button: Start, Crater,
and Preflow/Postflow. The applicable LED
illuminates to indicate which welding se-
quence is active.
• In the weld sequence display mode, the Se-
quence push button LED is Off. When the
Sequence push button is pressed, the Se-
quence push button flashes and the Start
LEDs flash. In this condition, the unit is in the
Start sequence display mode, and Start se-
quence parameters are displayed (see Sec-
• If the lower display push button is pressed,
the Adjust control can be used to select be-
tween preflow (PRE) and postflow (POST).
When POST is selected, the upper display
can be used to specify postflow time.
• The LED illuminates to indicate that a weld- • When the Sequence push button is pressed
ing sequence display mode other than Weld
is active. Welding sequences other than
Weld must be set prior to initiating the arc.
When the unit enters a welding state, all se-
quence display modes are terminated and
a second time, the Crater sequence LED
flashes. The Sequence push button LED re-
mains flashing. In this condition, the unit is • When the Sequence push button is pressed
in the Crater sequence display mode, and
Crater sequence parameters are displayed.
a fourth time, the unit returns to the welding
sequence display mode.
OM-230 009 Page 25
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6-12. Auxiliary Menus
1
2
3
4
5
6
7
8
9
Program Display
Program Push Button
Sequence Push Button
Upper Display
4
5
7
1
2
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
Program
V/Trim
Time (sec)
Setup Push Button
Wire Speed
Amps
6
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
9
3
Sequence
Adjust
Setup
8
Reset To Factory Settings
The upper display indicates “RUNI”. The
lower display indicates “AUTO”, meaning
the factory set automatic run-in speed is
selected.
Pressing the lower display button allows
manual setting of the run-in wire speed.
Speed may be adjusted from 10% to
100% of weld wire speed.
Pressing the lower display button again
allows disabling of the run-in feature.
When the lower display indicates “OFF”,
run-in is disabled.
•
There is an additional function built in
called ”maximum trigger hold time” which
is the maximum length of time the trigger
can be held and the trigger hold function
still work when the trigger is released (the
trigger hold function must be on). The
maximum trigger hold time is set at 4.0
seconds after the trigger hold delay time.
For example, if a trigger hold delay time of
2.0 seconds is defined, and the operator
held the trigger in for more than 6.0 sec-
onds, the trigger hold function would not
be in effect and the wire feeder would stop
when the trigger is released.
A reset menu is displayed if the following
four push buttons are pressed simulta-
neously: Program, Sequence, upper dis-
play, and Setup. The upper display indi-
cates “WIPE” . The lower display indicates
“OFF”. The lower push button is active indi-
cating that the Adjust control can be used to
change the unit to “WIPE ON”. When “WIPE
ON” is set, if the original four push buttons
are simultaneously pressed a second time,
the unit will reset all settings to factory de-
fault except the arc time and arc cycle
counts. If a reset is not desired, set the dis-
play to “WIPE OFF” and simultaneously
press the Program, Sequence, upper dis-
play, and Setup push buttons to exit the re-
set menu.
Burnback
Burnback time and voltage can be specified
when the lower display indicates “BURN”
and the upper display indicates the burn-
back time or voltage. The Adjust control is
used to set the desired burnback time or
voltage. Burnback settings are program
specific. The active program is displayed in
the Program display and can be adjusted
Trigger Program Select
The upper display shows “TSEL”. Lower
display shows “On” or “Off”. The Adjust con-
trol is used to select either “On” or “Off”.
Auxiliary Menu
Trigger Program Select allows the operator
to select programs by clicking the trigger
(pulling and releasing the trigger in a maxi-
mum of 0.2 seconds). The feeder will switch
between any programs that have a mini-
mum of 0.2 seconds of preflow time set in
the weld sequence.
• An auxiliary menu is provided if both the
Sequence and Setup push buttons are
pressed simultaneously. The Setup push
button and sequence push button LEDS
flash when the auxiliary menu is dis-
played.
Trigger Hold Setup
Trigger hold delay time is indicated by
”HOLD” in the lower display and the hold
delay time in the upper display. The adjust
control can be used to specify a new delay
time for trigger hold. Trigger hold delay time
is the minimum amount of time the trigger
must be held for trigger hold to work when
the trigger is released (the trigger hold func-
tion must be on). For example, if a trigger
hold delay time of 2.0 seconds is defined,
the operator must hold the trigger for at least
2 seconds before releasing it in order for the
trigger hold function to work. Once the trig-
ger hold function is in effect, the wire feeder
will stay On until the trigger is pressed and
released again.
Pushing the Setup push button will step
through the menu. Pushing the sequence
push button will step through the menu in re-
verse.
• Any combination of programs may be
used.
• If only programs 1 and 3 have a minimum
of 0.2 seconds of preflow time, clicking
the trigger will toggle between programs
1 and 3.
. The auxiliary menu may be exited at
any time by pressing both the Se-
quence and Setup push buttons simul-
taneously.
• If only programs 1, 2, and 4 have a mini-
mum of 0.2 seconds of preflow time, click-
ing the trigger will switch from 1 to 2 to 4
to 1 to 2.
Run-In
• The run-in modes are program specific
(i.e. each program may be set to its own
run-in mode).
• Trigger Program Select cannot be used
while welding or with Dual Schedule.
OM-230 009 Page 26
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Range Locks
Once any program has a lock enabled, the
remaining programs with all locks “OFF”
will not be accessible. To enable additional
programs, set the lock values for one or
more Voltage/Trim Command or Wire
Speed to appropriate ranges for each pro-
gram.
password between 0 and 999 by turning the
Adjust control.
Range locks are indicated by “LOCK” in the
upper display for wire speed or “LOCK” in
the lower display for voltage range.
If a code is set, when the user re-enters the
auxiliary menu, the password code must be
selected to gain access to the auxiliary
menu. Press Setup and Sequence buttons
simultaneouslyto enter the auxillary menu.
A failed attempt returns the user to the weld
screen and a counter is incremented. A
counter in the program display shows the
numberof incorrect attempts. The user has
five attempts to enter the correct password
code before being locked out of the auxilia-
ry menu, indicated by “LOCK” in the lower
display.
In a MIG program, the voltage range lock
ranges from +/− 0 to 10 volts.
Only one of the values needs to be set to
enablethe program. For example, setting a
Trim of 100 and leaving the Wire Speed at
OFF will allow the welder to adjust the Wire
Speed to full range
In a pulse program, the trim range lock
ranges from +/− 0 to 100.
The wire speed range lock ranges from +/−
0 to 195 IPM.
Wire Feed Speed Units
Locks are program dependent and wire
speed locks are independent from voltage/
trim command locks (i.e. you can have a
wire speed lock with or without locking the
voltage/trim command and vice versa).
Wire feed speed setting indicated by “WFS”
in the upper display is set to “IPM” inches−
per−minuteor ”MPM” meters−per−minute.
This setting is independent of the program
selected.
The power may be cycled to continue weld-
ing, but the user will remained locked out of
the auxiliary menu.
Press the Upper Display Pushbutton to se-
lect Voltage/Trim Command Range Locks.
The counter can be reset in the weld screen
by pressing the Program, Sequence, upper
display, and Set-up push buttons simulta-
neously. Resetting the counter is indicated
by “CODE” in the upper display and “RSET”
in the lower display. Pressing the Program,
Sequence, upper display, and Set-up push
buttons simultaneously again resets the
counter to 0.
Software Revision Level
• The unit displays the software version
being used by the interface PCB (PC20).
Press the Lower Display Pushbutton to se-
lect Wire Speed Range Locks.
• When the Setup button is pressed again,
the menu repeats.
To set a Voltage/Trim Command Range
Lock, you must choose the type of com-
mand being locked, voltage or trim based
on the type of weld process selected at the
power source. This is done by repeatedly
pressing the Upper Display Pushbutton to
cycle between OFF, T (trim) or V (voltage),
as indicated on the Upper Display.
Code
Upon leaving the auxiliary menu, the user is
asked if a password code, indicated by
“CODE” in the top display should be acti-
vated.
To reset the password, follow the directions
under Reset To Factory Settings at the be-
ginning of this section. Note: this will reset
all settings and programs to the factory de-
faults.
By default the code is “OFF” in the lower
display. The user may enter a numerical
Use the adjust knob to set the range value.
OM-230 009 Page 27
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6-13. Remote-14 Receptacle Information
1
2
Remote Switch
Remote-14 Receptacle
If the remote switch is set to MIG,
the feeder operates normally. A re-
mote control may be left attached
while the remote switch is in the
MIG mode, as the remote has no af-
fect on the operation of the wire
feeder.
If the remote switch is set to Stick/
TIG, the feeder controls and meter
displays are disabled, allowing con-
trol from a standard remote control.
When a remote control is con-
nected to the remote-14 receptacle,
the PipePro 450 RFC will automati-
cally adjust output control in a pri-
mary/secondary configuration, but
the power source must be set for
remote operation (see the PipePro
450 RFC Owner’s Manual for infor-
mation).
In this configuration, the Amp Ad-
just control on the PipePro 450 RFC
power source becomes the prima-
ry, and sets the maximum amper-
age output of the unit. The remote
control becomes the secondary,
and provides an amperage range
adjustmentof 0 to 100% of what is
set on the Amp Adjust control on the
power source.
2
1
. When in Stick/Tig mode, re-
mote program select is still
functionalfrom the feeder.
Do not connect a Stick elec-
trode holder and a MIG gun
to the same output terminal
at the same time, as both
will be live when the contac-
tor is on. An external polar-
ity reversing isolation con-
trol should be used to iso-
late the outputs.
804 667-B
OM-230 009 Page 28
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SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence Push Button see
If time is set to zero in Weld
sequence, welding continues until
Sequence
Parameters
gun trigger is released.
Volts
X
IPM
Seconds
0-9.9
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
1. Preflow
2. Run-In
3. Start
X
X
X
X
0.00-5.00
0-100.0
4. Weld
X
X
X
5. Crater
6. Burnback
0-5.00
0-0.25
7. Postflow
0-9.9
X = Setting available.
Weld Time
Crater
Time
Burnback
Time
Preflow
Time
Start
Time
Postflow
Time
Time
Burnback
Postflow
Run-In
Weld
Start
Crater
Trigger
Sequence
End
Preflow
Trigger
Pressed
Released
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS
8-1. Optional Dual Schedule Switch Diagrams
. A DSS-8 will not function with
trigger hold and dual schedule.
A DSS-9 is recommended for
this application.
Dual Schedule With DSS-9
(Maintained Contact)
Dual Schedule With DSS-8
(Maintained Contact)
1
1
1
2
2
2
TR
3
B
A
3
4
A
4
B
OM-230 009 Page 29
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8-2. Diagnostics
1
LED3 On Right Side Motor
Control Board PC101
3
2
3
LED4 On Dual Board PC70
2
LED3 On Left Side Motor
Control Board PC1
1
804 804-A
Left Side Motor Control Board PC1
ERR
ERR
ERR
ERR
COM1
Indicates a com-
munication error.
TRG1
Indicates a trigger
error.
TCH1
MTR1
Indicates a motor
error.
Indicates a
tachometer error.
. Note: The error messages
are shown on the upper
and lower displays to indi-
cate specific errors. Ex-
planations are in the text
below:
Right Side Motor Control Board PC101
ERR
ERR
ERR
ERR
COM2
Indicates a com-
munication error.
TRG2
Indicates a trigger
error.
TCH2
MTR2
Indicates a motor
error.
Indicates a
tachometer error.
Dual Board PC70
ERR
Indicates a
communication
COM3
error.
LED3-Related Error Indications
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach Error
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The user may
continue to weld with this error. The motor
speed is regulated through the monitoring of
voltage and current.
Error conditions are indicated by LED3 on
PC1, PC101, and LED4 on PC70. To view
LED3, 4 turn Off unit, remove wrapper, and
turn unit On.
The LED blinks in a 2.5 second cycle. The
number of blinks in this period indicates the
type of error.
The priority of the errors is related to the num-
ber of blinks indicating the error. The more
blinks, the more severe the error (motor error
is top priority). A higher priority error overrides
a lower one (if a motor error and a communica-
tion error existed, the light would blink four
times for the motor error).
Since blink On time and blink Off time are
equal in a four-blink cycle, the four−blink se-
quence appears as a constant blink.
4 blinks = Motor Error
• The communication error occurs 2.5 sec-
onds after a loss of communication between
the motor and the Front Panel board or Dual
board. The user may continue to weld with
this error.
• The motor error indicates that the motor
has been drawing too much current for too
long.
• The trigger error occurs if the user has the
trigger held for more than two minutes with-
out striking an arc (providing current over-
ride is not enabled), or if the user holds the
trigger past the postflow phase in a timed
weld. This error also occurs if the trigger is
held when the feeder is powered up. The er-
ror may be cleared by releasing the trigger.
OM-230 009 Page 30
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SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Routine Maintenance
Disconnect power before maintaining.
n = Check
~ = Clean
l = Replace
Reference
Every
3
Months
l Unreadable Labels
~ Weld Terminals
nl Weld Cable
l Cracked Parts
n 14-Pin Cord
n Gas Hose and Fittings
n Gun Cable
Every
6
Months
Or
~ Inside Unit
~ Drive Rolls
OM-230 009 Page 31
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9-2. Troubleshooting
Disconnect power before troubleshooting.
Remedy
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check cable connections. Check cables for continuity, and repair or replace cables if necessary
Wire feeder is on, display does not light Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Electrode wire feeding stops, or feeds
erratically during welding.
Change to correct size drive roll (see Table 9-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Check for correct input voltage.
Motor runs slowly.
Wire feeder power is on, displays light
up, feeder jogs, purges, but unit is in-
operative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
When triggered, wire feeds but no gas, If the welding arc does not establish in 3 seconds after the gun trigger is activated the unit will feed
no contactor.
wire, but turns off contactor and gas valve. If the gun trigger is still activated after two minutes, the
wire will stop feeding.
When triggered, wire feeds, but no
contactor.
If the gun trigger does not enable output, make sure remote switch is in the correct position
OM-230 009 Page 32
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Notes
MATERIAL THICKNESS GAUGE
OM-230 009 Page 33
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229 867-A
OM-230 009 Page 35
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Item
No.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 159 647 . . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . 159 646 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 159 360 . . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 4 . . . . . . . . . . . . . . . 201 762 . . Drive Assy, Wire S/L 4 Roll W/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 143 160 . . Hub+Spindle Assy, (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 180 576 . . . . Shaft, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . Spring, Cprsn .970 Od X .120 Wire X 1.250pld . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . Washer, Flat Stl Keyed 1.500 dia X .125thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . Washer, Fbr .656 Id X 1.500 Od X .125thk . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 071 730 . . . . Tubing, STL .875 Od X 12Ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . 135 205 . . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 141 411 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 208 339 . . Extension, Dual Clamp L.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 208 338 . . Extension, Dual Clamp R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 156 243 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . 145 639 . . Strip, Buna−n .062 X 3.000 X 4.000 Compressed Sht . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 139 226 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 134 306 . . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box (Refer to Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 201 768 . . Drive Assy, Wire R 4 Roll W/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 164 059 . . Hose, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-230 009 Page 37
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. Hardware is common and
not available unless listed.
8
7
10
12
16
6
9
1
15
11
14
13
17
18
19
5
3
2
32
31
30
20
4
21
22
23
7
24
25
29
26
27
28
804 742-A
Figure 11-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 204 722 . . Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Upper (Order By Model Or Serial Number) . . . . . . . . . . . . . . 1
. . . 3 . . . . PC21 . . . . . 230 877 . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . PC20 . . . . . 229 459 . . Circuit Card Assy, Display/U W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . S1 . . . . . . 111 997 . . Switch, Rocker Spst 10A 250VAC On-Off Visi Red Rock . . . . . . . . . . . . 1
. . . 6 . . . . PC70 . . . . . 221 836 . . Circuit Card Assy, W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . PC1,101 . . . 232 642 . . Circuit Card Assy, Motor Ctrl W/Program . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 221 791 . . Choke, Common Mode W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . L2 . . . . . . 131 447 . . Core, Toroidal 1.332 Id X 1.932 Od X .625 Thk . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 139 091 . . Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 000 527 . . Blank, Snap−In Nyl .875 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 229 863 . . Cable, Power (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 139 041 . . . . Bushing, Strain Relief .450/.709 Id X1.115 Mtg Hole . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 236 551 . . . . Cable, Port No 18−14 14/C Type Tpe 2−14 12−18 Cndct . . . . . . . 2.583 Ft
. . . 15 . . . . . . . . . . . . . . . 200 545 . . . . Conn, Circ 97/Met Clamp Str Size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . PLG31 . . . . 202 592 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG12 . . . . 215 031 . . . . Conn, Circ 97/Met 14 Pin Size 20 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG35 . . . . 115 094 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG33 . . . . 115 092 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 211 989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . 605 227 . . Nut, 750−14 Knurled1.68Dia .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 030 170 . . Bushing, Snap−In Nyl .750 Id X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . 3
OM-230 009 Page 38
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box (Continued)
. . . 20 . . GS1,101 . . . 219 047 . . Valve, 40VDC 2Way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . . 010 494 . . Bushing, Snap−In Nyl 1.375 Id X 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . 134 201 . . Stand−Off Support, Pc Card .312/.375W/Post&lock .43 . . . . . . . . . . . . . 17
. . . 23 . . . . . . . . . . . . . . . 204 721 . . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 L13,21,27,113 . 213 030 . . Core, Toroidal 19.00mm Id X 29.01mm Od X 7.62mm Th . . . . . . . . . . . 4
. . . 25 . . . . PC3 . . . . . 229 724 . . Circuit Card Assy, Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 229 745 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Lower (Order By Model Or Serial Number) . . . . . . . . . . . . . . 1
. . . 28 . . . S2,102 . . . . 200 295 . . Switch, Rocker Spdt 15A 12V (On)−Off−(On) . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . S100 . . . . . 201 641 . . Switch, Rocker Spdt 15A 12V (On)−Off−(On) W/Leds . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 213 134 . . Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Upper (Order By Model Or Serial Number) . . . . . . . . . . . . . . 1
. . . 32 . . RC13,113 . . . 048 282 . . RCPT W/SKTS, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 134 464 . . Label, Warning General Precautionary Static&Wire Fe . . . . . . . . . . . . . . 1
. . . . . . . . PLG6,28 . . . 115 094 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG1,32,78,
. . . . . . . . . 79,101 . . . . 202 592 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . 136 810 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG7,27,74,
. . . . . . . . . . 75,76 . . . . . 115 091 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . . 115 093 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . . 131 204 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG11,21,71,111 131 055 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG10,110 . . 130 203 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . . 164 899 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG34 . . . . 131 052 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG72 . . . . 115 092 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG73 . . . . 148 439 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG70 . . . . 150 319 . . Conn, Rect Univ 039 2P/S 1Row Plug Cable . . . . . . . . . . . . . . . . . . . . . . 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-230 009 Page 39
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13
. Hardware is common and
19
not available unless listed.
11
14
15
16
See Table 11-1 For
17
11
Drive Roll & Wire Guide Kits
18
9
7
8
6
5
4
3
19
2
12
20
1
10
21
22
37
23
24
25
26
36
35
34
27
33
28
6
32
29
5
30
31
4
3
2
1
803 790-A
Figure 11-3. Drive Assembly, Wire
Item
No.
Dia.
Part
No.
Mkgs.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 010 668 . . Screw, Cap Stl Sch .250-20 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 2 . . . . . . . . . . . . . . . 172 075 . . Carrier, Drive Roll W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . . 149 962 . . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . . 149 486 . . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 132 750 . . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 150 520 . . Spacer, Flat Stl .257 Id X .619 Od X .105 . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . 133 493 . . Ring, Retaining Ext .250 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 133 350 . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . M1,101 . . . . 201 230 . . Motor, Gear 1/8hp 24VDC Standard Speed . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 491 . . . . Kit, Brush Replacement (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 492 . . . . . Cap, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . *153 493 . . . . . Brush, Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 184 136 . . . . Kit, Brush Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 155 098 . . Kit, Cover Motor Gearbox (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 550 . . . . Cover, Motor Gearbox (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 155 099 . . . . . Gasket, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 155 100 . . . . . Screw, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . 154 031 . . . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 133 493 . . . . Ring, Rtng Ext .250 Shaft Grv X .025Thk . . . . . . . . . . . . . . . . . . . . . . 1
OM-230 009 Page 40
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Item
No.
Dia.
Part
No.
Mkgs.
Description
Quantity
Figure 11-3. Drive Assembly, Wire (Continued)
. . . . . . . . . . . . . . . . . . . . . 203 642 . . Pressure Arm, R & Vert L 4 Roll (Includes) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 203 631 . . Pressure Arm, S/L & Vert S/R 4 Roll (Includes) . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 203 641 . . . . Washer, Flat Indicator Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 182 415 . . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 203 640 . . . . Knob, W/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 182 156 . . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . 182 155 . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . 132 746 . . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . . 203 633 . . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 203 632 . . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 133 739 . . . . Washer, Flat Buna .375 Id X .625 Od X .062Thk . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . . 203 637 . . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . PC51,151 . . . 201 225 . . Circuit Card, Digital Tach (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG5 . . . . . 131 204 . . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 604 311 . . . . Grommet, Rbr .250 Id X .375Mtg Hole .062 Groove . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 132 611 . . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 603 115 . . Weather Stripping, Adh .125 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 167 387 . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . . 168 825 . . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 133 308 . . Ring, Retaining Ext .375 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 134 834 . . Hose, Sae .187 Id X .410 Od (order by ft) . . . . . . . . . . . . . . . . . . 2 Ft (0.6 m)
. . . 27 . . . . . . . . . . . . . . . 149 959 . . Fitting, Brs Barbed M 3/16Tbg X .312-24 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 179 265 . . Adapter, Gun/Feeder LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 179 264 . . Adapter, Gun/Feeder RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 108 940 . . Screw, Cap Stl Hexhd .250-20 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . . . . . . . . . . . . 604 538 . . Washer, Flat Stl Sae .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 151 437 . . Knob, Plstc T 1.125 Lg X .312-18 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 151 290 . . Screw, Mach Stl Hexwhd 10-32 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . . 179 277 . . Cover, Drive Roll (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 937 . . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 601 872 . . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 602 213 . . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . 602 243 . . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . 601 966 . . Screw, Cap Stl Hexhd .375-16 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . 1
*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-230 009 Page 41
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G u i d e
I n t e r m e d i a t e
G u i d e
I n l e t
OM-230 009 Page 42
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Effective January 1, 2008
(Equipment with a serial number preface of LJ or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
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.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
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.
Your distributor also gives
you ...
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.)
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
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.
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.
1. 5 Years Parts — 3 Years Labor
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.
*
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
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.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
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,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
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.
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
*
*
*
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,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2008-01
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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.)
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
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
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
© 2008 Miller Electric Mfg. Co.2008−01
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