OM-1500-9
207 749K
2006−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
S-74DX
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 − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
5
5
7
8
8
3-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-1. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-2. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-5. Wire Type, Size, And Feed Speed Capability Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-6. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-7. Setting Internal DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-8. Power Source Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-3. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-4. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-7. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-8. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-9. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-10. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-11. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-1. Optional Dual Schedule Switch Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 9 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
S-74DX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 5: Wire Feeders. IEC 60974-5 Ed. 1
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems −
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_wire_6/05
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
Safety Standards.
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Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
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Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
During operation, keep everybody, especially children, away.
D
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
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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.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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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.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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D
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FUMES AND GASES can be hazardous.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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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.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
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Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
OM-1500-9 Page 1
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ARC RAYS can burn eyes and skin.
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 from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D
Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
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Wear approved safety glasses with side shields under your
helmet.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
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Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
NOISE can damage hearing.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
damagehearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
Wear approved ear protection if noise level is
high.
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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.
CYLINDERS can explode if damaged.
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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).
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
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Do not use welder to thaw frozen pipes.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
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Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
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Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
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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.
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OM-1500-9 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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Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
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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 Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
D
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.
OVERUSE can cause OVERHEATING
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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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Do not block or filter airflow to unit.
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The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
STATIC (ESD) can damage PC boards.
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Have the installation regularly checked and maintained.
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Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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.
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ARC WELDING can cause interference.
MOVING PARTS can cause injury.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
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.
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Do not press gun trigger until instructed to do
so.
Be sure this welding machine is installed and grounded
according to this manual.
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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.
1-4. California Proposition 65 Warnings
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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.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
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.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-1500-9 Page 3
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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).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101(phone: 617−770−3000, website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-6. 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.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1500-9 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som _3/05
Y
Avertissement: se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
Symbole graphique d’avertissement ! Attention ! Cette pro-
cédure comporte des risques possibles ! Les dangers éven-
tuels sont représentés par les symboles graphiques joints.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Y
Indique un message de sécurité particulier
. Signifie NOTE ; n’est pas relatif à la sécurité.
2-2. Dangers relatifs au soudage à l’arc
Y
Les symboles représentés ci-dessous sont utilisés dans ce manuel
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
observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonction-
ner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les per-
sonnes, notamment les enfants de l’appareil.
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.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement en
place.
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.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
D
D
D
D
Y
Y
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
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
D
D
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
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
D
D
Ne pas toucher aux pièces électriques sous tension.
Porter des gants isolants et des vêtements de protection secs et sans
trous.
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 se servir de source électrique à courant électrique dans les zo-
nes humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère né-
cessaire, se servir de la fonction de télécommande si l’appareil en est
équipé.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
D
D
Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions indi-
quées dans la partie Entretien avant de toucher les pièces.
D
D
D
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereuse pour la santé.
D
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si l’on
porte des vêtements mouillés ; sur des structures métalliques telles que
sols, grilles ou échafaudages ; en position coincée comme assise, à ge-
noux 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 (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 recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer le poste correctement et le mettre à la terre convenablement
selon les consignes du manuel de l’opérateur et les normes nationales,
provinciales et locales.
D
D
D
D
Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-
peurs.
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.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu-
vé.
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 dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un sur-
veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-
quant des blessures ou des accidents mortels. S’assurer que l’air de
respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz haute-
ment toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-
vanisé, plaqué en plomb ou au cadmium à moins que le revêtement 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 revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxi-
ques en cas de soudage.
D
D
D
D
D
D
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
OM-1500-9Page 5
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LES RAYONS D’ARC peuvent entraî-
ner des brûlures aux yeux et à la peau.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-
quer des brûlures dans les yeux et sur la peau.
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.
Des étincelles sont projetées pendant le soudage.
D
Porter un casque de soudage approuvé muni de verres filtrants ap-
proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous vo-
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
tre 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.
Porter des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
D
Ne pas toucher des parties chaudes à mains
nues.
D
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D
D
Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
Porteurs de stimulateur cardiaque, rester
à distance.
d’étincelles,des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrodeavec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
D
Les porteurs d’un stimulateur cardiaque doi-
vent d’abord consulter leur médecin avant de
s’approcherdes opérations de soudage à l’arc,
de gougeage ou de soudage par points.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi-
gneusementavec des protections homologuées.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
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 prépa-
rés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
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 provoquant des
risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
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 exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
D
D
D
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 soudage,
les manipuler avec précaution.
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
ve, des chocs mécaniques, des dommages physiques, du lai-
tier, des flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support sta-
tionnaireou dans un porte-bouteilles pour les empêcher de tom-
ber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
D
D
D
D
D
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
D
Avant de souder, retirer toute substance combustible de ses poches
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
telles qu’un allumeur au butane ou des allumettes.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifi-
que ; les maintenir ainsi que les éléments associés en bon état.
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
Le couvercle du détendeur doit toujours être en place, sauf lors-
que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
Utiliser les équipements corrects, les bonnes procédures et suf-
fisammentde personnes pour soulever et déplacer les bouteil-
les.
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 sécuri-
té.
Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un ex-
tincteur à proximité.
D
D
DES
PARTICULES
VOLANTES
peuvent blesser les yeux.
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
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D
D
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
OM-1500-9 Page 6
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Ne pas installer l’appareil à proximité de
produits inflammables.
D
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
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.
D
Lire le manuel d’utilisation avant d’utiliser ou
d’intervenirsur l’appareil.
D
D
Utiliser uniquement des pièces de rechange
Miller/Hobart.
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.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
D
Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipe-
ments de radio-navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
D
D
Prévoir une période de refroidissement ;
respecter le cycle opératoire nominal.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’instal-
lation.
L’utilisateurest tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenirsoigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
distance correcte et utiliser une terre et un blindage pour réduire
les interférences éventuelles.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Veiller à ce que tout l’équipement de la zone de
D
Ne pas s’approcher des organes mobiles.
soudage soit compatible électromagnétiquement.
D
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
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).
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
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-
mentaires telles que le déplacement du poste, l’utilisation de
câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en enga-
geant le fil de soudage.
2-4. Proposition californienne 65 Avertissements
Y
Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :
fumées et des gaz qui contiennent des produits chimiques dont
Y
Les gaz d’échappement des moteurs contiennent des produits
l’État de Californie reconnaît qu’ils provoquent des malformations
congénitales et, dans certains cas, des cancers. (Code de santé et
de sécurité de Californie, chapitre 25249.5 et suivants)
chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres pro-
blèmes de procréation.
Pour les moteurs diesel :
Y
Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des can-
cers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Y
Les gaz d’échappement des moteurs diesel et certains de leurs
composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou au-
tres problèmes de procréation.
OM-1500-9Page 7
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2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone
:
:
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou
à
Toronto 416-747-4044, site Internet
ternet : www.global.ihs.com).
www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (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, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000,site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101(téléphone : 617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220,site Internet : www.osha.gov).
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
champs magnétiques et électriques.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
Le courant de soudage, pendant son passage dans les câbles de souda-
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
certain souci à propos de tels champs. Cependant, après avoir examiné
votre corps.
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
4. Garder le poste de soudage et les câbles le plus loin possible de
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
vous.
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ».
5. Connecter la pince sur la pièce aussi près que possible de la sou-
Toutefois, des études sont toujours en cours et les preuves continuent à
dure.
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-
les procédures suivantes :
cin approuve, il est recommandé de suivre les procédures précédentes.
OM-1500-9 Page 8
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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-1500-9 Page 9
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3-2. Rating Label For CE Products
For label location
S/N:
U1
I =
1
50/60 Hz
IP 21
24 V
10.0A
1
=
U2
=
I =
750 A
2
100 V
X 100 %
ST-178 794-A
3-3. Symbols And Definitions
Some symbols are found only on CE products.
Note
Amperes
Volts
AlternatingCurrent
Program
Duty Cycle
A
IP
V
Hz
X
Degree Of
Protection
Hertz
Wire Feed
Jog
Output
Trigger
Line Connection
Set Up
Sequence
Trigger Hold On
Trigger Hold Off
Crater
Purge
Time
Press To Set
Preflow Time
Start
Postflow Time
Rated Current
Read Instructions
Load Voltage
Increase
Primary Current
Dual Schedule
I1
I2
U2
A
B
Primary Voltage
U1
OM-1500-9 Page 10
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SECTION 4 − INTRODUCTION
4-1. Specifications
Type of
Input Power
Welding Power
Source Type
Wire Diameter
Range
Welding
IP
Overall
Dimensions
Wire Feed Speed Range
Weight
Circuit Rating Rating
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Constant Voltage
(CV)
DC With 14-Pin
And Contactor
Control
Standard: 50 To 780 ipm
(1.2 To 19.8 mpm)
.023 To 1/8 in
100 Volts,
750 Amperes,
100% Duty
Cycle
IP 21
Length: 27 in
(686 mm)
45 lb
(20.4 kg)
(0.6 To 3.2 mm)
Width: 12-1/2 in
(318 mm)
Optional High Speed: 92 To
1435 ipm (2.3 To 36.4 mpm)
Max Spool
Weight: 60 lb
(27 kg)
Height: 14 in
(356 mm)
Optional Low Speed: 19 to
300 ipm (0.4 to 7.6 mpm)
SECTION 5 − INSTALLATION
5-1. Site Selection
Y
Y
Do not put feeder where
welding wire hits cylinder.
Do not move or operate
equipmentwhen it could tip.
3
1
2
Wire Feeder
Rubber Feet
4
Choose slot that allows all rubber
feet to sit securely on top of welding
power source.
1
3
4
Wire Spool/Reel
5
Gas Cylinder w/Hose And
Regulator (Customer
Supplied)
2
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
5
6
Welding Power Source
Running Gear
. Factory voltage settings are V-
Min 10 and V-Max 38. If you are
using a power source with a dif-
ferent voltage range, see Sec-
adjustments.
6
Ref. ST-152 468-A / ST-152 467-C
OM-1500-9 Page 11
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5-2. Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable − 10 ft
(3.0 m)
Shielding Gas Valve Fitting
Requires fitting with 5/8-18 right-
hand threads. Connect customer-
supplied gas hose.
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
3
4
5
6
Weld Cable Terminal
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
7
7
Rating Label Location
To rotate the drive assembly, loos-
en drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
2
1
3
4
5
6
Tools Needed:
9/16, 5/8 in
3/16 in
802 824-A / 802 825-A
OM-1500-9 Page 12
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5-3. 14-Pin Plug Information
Pin*
Pin Information
A
B
G
C
D
E
H
F
24 volts ac with respect to socket G.
Contact closure to A completes 24 volts ac contactor control circuit.
Circuit common for 24 volts ac circuit.
J
A
K
I
B
C
L
H
N
+10 volts dc input from power source to wire feeder with respect to socket D.
Remote control circuit common.
M
E
G
D
F
0 to +10 volts dc output 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.
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
*The remaining pins are not used.
5-4. Gun Recommendation Table
Process
Gun
GMAW − Hard or Cored Wires
Roughneck C-Series Guns: 300,
400, 500, And 600 Amp.
FCAW − Self-Shielding Wires
FC-1260 Or FC-1150
5-5. Wire Type, Size, And Feed Speed Capability Table
Motor Speed
Standard
Wire Type
Wire Size
Feed Speed Capability
All
All
All
.023 To 5/64 in (0.6 To 2 mm)
3/32 To 7/64 in (2.4 To 2.8 mm)
1/8 in (3.2 mm)
50 To 780 ipm (1.2 To 19.8 mpm)
50 To 700 ipm (1.2 To 17.8 mpm)
50 To 300 ipm (1.2 To 7.6 mpm)
Standard
Standard
Optional High
Speed
All
All
.023 To 5/64 in (0.6 To 2 mm)
.023 To 1/8 in (0.6 To 3.2 mm)
92 To 1435 ipm (2.3 To 36.4 mpm)
19 To 300 ipm (0.4 To 7.6 mpm)
Optional Low
Speed
OM-1500-9 Page 13
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5-6. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Indicator
Scale
Pressure
Adjust
Rear
Rolls
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Drive Rolls
Gun Cable
Tools Needed:
3/16, 5/64 in
15/16, 3/8 in
End Of Liner
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
liner for the welding wire size. When
installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls 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 / 802 954 / S-0627-A
OM-1500-9 Page 14
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5-7. Setting Internal DIP Switches
1
2
DIP Switch S1
DIP Switch S4 (Not For Customer Use)
DIP switch S1 allows the user to make a num-
ber of choices affecting unit operation.
w Defining Motor Speed (S1-7 & 8)
Switches 7 and 8 allow the user to define
whether the motor in use is standard speed
(50-780 inches per minute), or high speed
(92-1435 inches per minute), or low speed
(19-300 inches per minute).
. 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.
1
O
N
1
2
3
4
5
6
7
8
. 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.
2
802 808
Position Settings And Results For DIP Switch S1
7
7
8
8
7
8
7 Off, 8 Off = Standard
speed motor (50-780 inch-
es per minute, or 1.2-19.8
meters per minute)
7 On, 8 On = Low Speed
Motor (19-300 inches per
minute, or 0.4-7.6 meters per
minute).
7 Off, 8 On = High speed
motor (92-1435 inches per
minute, or 2.3-36.4 meters
per minute)
OM-1500-9 Page 15
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5-8. Power Source Selection Menu
1
2
Upper Display
Lower Display
Non-CE Model Shown
1
. When the feeder is turned on,
the Power Source Selection
Menu allows the operator to se-
lect a default power source.
Selecting
a
default power
source, automatically sets the
correct Vmin and Vmax set-
tings for adjusting the output
voltage of the power source.
Program
Volts
Time (sec)
First Time Feeder Is Turned On
The feeder automatically goes into
the Power Source Selection Menu.
The feeder displays “dELT” on the
Upper Display and “452” on the
Lower Display, meaning that a Del-
taweld 452 is the default power
source, and has a voltage range of
10V as Vmin and 38V as Vmax.
Wire Speed
Amps
2
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
At power up, the operator has three
seconds to select a default power
source from the list shown on the
display. Operator may scroll
throughthe list of power sources by
using the Adjust control. After se-
lecting a power source the operator
has three seconds to change to a
different power source or begin
welding. After making a power
source selection, the operator may
press the Program Button to avoid
having to wait the three seconds.
When turning off the feeder, the de-
fault power source will be retained.
Sequence
Adjust
Setup
Upper Display
Voltage Range
* * Power Source
Lower Display
Deltaweld 452
Deltaweld 302
Deltaweld 652
Dimension 302
Dimension 452
Dimension 652
Dimension 1000
XMT 304
dELT
dELT
dELT
dIM
452
302
652
302
452
652
1000
304
456
MP
Vmin =10
Vmax =38
Vmax =32
Vmax =44
Vmax =32
Vmax =38
Vmax =65
Vmax =60
Vmax =35
Vmax =38
Vmax =35
Vmax =38
Vmax =38
Vmax =38
Vmax =44
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =25
If voltage settings have already
been set with the Vmin and Vmax in
the Auxiliary Menu, selecting a de-
fault power source with the Power
Source Selection Menu overrides
the Vmin and Vmax voltage set-
tings.
dIM
dIM
dIM
XMT
XMT
I354
I456
I456
PHX
SUM
XMT 456
Next Time Feeder Is Turned On
Invision 354MP
Invision 456MP
Invision 456P
PHOENIX 456
SUMMITARC 1000
The feeder will display the last se-
lected default power source. The
operator has three seconds to se-
lect another power source, or press
the Program Button to exit the Pow-
er Source Selection Menu.
MP
P
456
1000
Disabling The Power Source
Selection Menu
Once the default power source has
been selected the Power Source
Selection Menu may be disabled
using the Auxiliary Menus. See
** For any power sources not listed, pick a matching voltage range, or see Sec 5-10 to
set Vmin and Vmax.
OM-1500-9 Page 16
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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
1
Power Switch
802 809-A
6-3. Program Push Button
1
Program Display
The number of the active program
is displayed.
Non-CE Models
CE Models
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
1
2
3
Program Push Button LED
The LED lights to indicate the Pro-
gram push button is active.
Program
3
3
2
OM-1500-9 Page 17
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6-4. Front Panel Controls
Nameplate For Non-CE Models
See
Section
See
Section
Program
See
Section
Volts
Time (sec)
Wire Speed
Amps
Start
Dual Schedule
Trigger Hold
Crater
Pre/Postflow
Sequence
Adjust
Setup
See
Section
See
Section
See
Section
Nameplate For CE Models
See
Section
See
Section
See
Section
See
Section
See
Section
See
Section
OM-1500-9 Page 18
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6-5. Upper Display
. To set the correct voltage range for a particular power
Non-CE Models
3
1
4
2
Volts
Time (sec)
5
CE Models
3
1
4
2
5
1
Upper Display
nates to indicate that information displayed
can be changed by the Adjust control.
play push button repeatedly until welding
time is the active parameter in the upper
display. At idle, the upper display toggles
between showing weld voltage or weld
time, with subsequent presses of the up-
per display push button.
The upper display shows voltage or time.
The unit displays both preset and actual arc
voltage. When the unit is in a welding state,
actual arc voltage is displayed. The upper
display shows welding sequence time when
the Time LED is illuminated.
4
5
Volts LED
Time LED
The LEDs below the display illuminate to in-
dicate which value is being shown.
• The unit defaults to displaying welding
voltage when a welding sequence display
mode is first entered.
At any time while welding, the unit permits
the adjustment of the weld sequence voltage
and overrides the display of actual arc volt-
age.
2
Upper Display Push Button
Press and hold button to adjust or display
weld time. Release button to display voltage.
• If the weld sequence has a time set (as in
spot time), after the weld program is com-
pleted, ERR TRG 1 will be displayed to in-
dicate the weld program is complete. Re-
lease 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-
3
Upper Display Push Button LED
The upper display push button LED illumi-
OM-1500-9 Page 19
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6-6. Lower Display
3
2
1
Non-CE Models
4
Wire Speed
Amps
5
3
1
4
2
CE Models
5
1
Lower Display
to indicate that information displayed can be
changed by the Adjust control.
just control is activated while welding, the
unit displays and permits adjustment of the
weld sequence wire feed speed regardless
of the active welding sequence.
The lower display shows wire speed or
amperage.The unit displays and adjusts only
preset wire speed at idle. When the unit is in a
welding state, actual wire speed is displayed
for the active welding sequence.
4
5
Wire Speed LED
Amps LED
• When the unit is displaying amperage, the
Amps LED illuminates. Amperage is only
displayed if the unit is in a welding state and
the amperage is above a minimum value of
25 Amps.
The LEDs below the display illuminate to indi-
cate which value is being shown.
2
Lower Display Push Button
• If the unit is in a welding state that does not
involve feeding wire, the unit displays the
weld sequence wire speed. At any time dur-
ing welding, the weld sequence wire speed • The display will read dashes for amperage
can be adjusted and overrides the preset
wire speed display. In other words, if the Ad-
Press button to choose between wire speed or
amperagefunctions.
3
Lower Display Push Button LED
readings below the amperage threshold,
prior to arc initiation.
The lower display push button LED illuminates
6-7. Setup Push Button
3
3
4
Trigger Hold
4
2
Dual Schedule
2
1
1
Setup
Non-CE Models
CE Models
1
Setup Push Button
the trigger hold status or press the lower dis- • When the Setup button is pressed a second
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
• When the Setup button is pressed, the Set-
up push button LED flashes and the Trigger
Hold LED flashes.
Setup Push Button LED
Trigger Hold LED
Dual Schedule LED
• When trigger hold is On, the user must
press and hold the trigger for a predefined
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.
• Pressing the Setup button again exits the
Setup mode. The dual schedule LED stops
flashingto indicate the dual schedule status
is Off.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
the upper display indicates HOLD and the
• While in the Setup mode, the active program
can be adjusted without deactivating the
trigger hold Setup mode operation. If the
trigger is activated, Setup mode(s) is termi-
nated.
• If a weld time is programmed, trigger hold is
disabled.
lower display indicates the trigger hold sta- • Trigger hold and dual schedule cannot be
tus On/Off. Use the Adjust control to change
used concurrently.
OM-1500-9 Page 20
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6-8. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parame-
ters, and to select various se-
quences. Refer to the section for
the function in question for informa-
tion related to using the Adjust con-
trol.
1
1
Adjust
Non-CE Models
CE Models
6-9. Sequence Push Button
1
2
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
Start
3
3
Crater
Pre/Postflow
Weld
2
1
Start
Time
Crater
Time
2
Time
Preflow
Time
1
Postflow
Time
Sequence
Welding Sequence Diagram
Non-CE Models
CE Models
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 shown in the dis-
plays.
If the lower display push button is pressed, the
Adjust control can be used to select between
preflow PRE and postflow POST. When
POST is selected, the upper display can be
used to specify postflow time.
• When the Sequence push button is pressed
a second time, the Crater sequence LED
flashes. The Sequence push button LED re-
mains flashing. In this condition, the unit is
in the Crater sequence display mode, and • When the Sequence push button is pressed
Crater sequence parameters are shown in
the displays.
• The LED illuminates to indicate that a weld-
ing sequence display mode other than Weld
is activate. 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 fourth time, the unit returns to the welding
sequence display mode.
OM-1500-9 Page 21
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6-10. Auxiliary Menus
1
2
3
4
5
6
7
8
9
Program Display
Program Push Button
Sequence Push Button
Upper Display
Non-CE Models
4
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
5
7
1
Setup Push Button
2
Program
Volts
Time (sec)
Wire Speed
Amps
6
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
9
3
Sequence
Adjust
Setup
8
CE Models
4
5
1
2
7
6
9
3
8
OM-1500-9 Page 22
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6-10 Auxiliary Menus (Continued)
Reset To Factory Settings
Arc Time
hold delay time of 2.0 seconds is defined,
and the operator held the trigger in for more
than 6.0 seconds, 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 simultaneously:
Program, Sequence, upper display, and Set-
up. The upper display indicates “WIPE” . The
lower display indicates “OFF”. The lower push
button is active indicating that the Adjust con-
trol 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 default except the arc time and arc
cycle counts. If a reset is not desired, set the
display to “WIPE OFF” and simultaneously
press the Program, Sequence, upper display,
and Setup push buttons to exit the reset menu.
• If the Setup push button is pressed, the unit
displays arc time in hours.
Arc time is indicated by the Program display
showing “HR”. Arc time is shown in the lower
display.
• When the Setup push button is pressed
again, the menu repeats to the first menu
selection of run-in wire speed selection.
Cycles
Trigger Program Select
• If the Setup push button is pressed, the unit
displays the number of cycles.
• If the Setup push button is pressed, the unit
allows Trigger Program Select to be dis-
abled or enabled.
Arc cycles are indicated by the Program dis-
play showing “CL”. The arc cycle count is
shown in the lower display.
The upper display shows “TSEL”. Lower dis-
play shows “On” or “Off”. The Adjust Control is
used to select either “On” or “Off”.
Run-In
• If the Setup button is pressed, the unit allows
setting the run-in modes. The run-in modes
are program specific. Each program may be
set to its own run-in mode.
Auxiliary Menu
Trigger Program Select allows the operator to
select programs by clicking the trigger (pulling
and releasing the trigger in a maximum of 0.2
seconds). The feeder will switch between any
programsthat have a minimum of 0.2 seconds
of preflow time set in the weld sequence. If pro-
grams 1 and 3 have a minimum of 0.2 seconds
of preflow time, clicking the trigger will toggle
between programs 1 and 3. If programs 1, 2,
and 4 have a minimum of 0.2 seconds of pre-
flow time, clicking the trigger will switch from 1
to 2 to 4 to 1 to 2. Any combination of programs
may be used. Trigger Program Select cannot
be used while welding or with Dual Schedule.
• An auxiliary menu is provided if both the Se-
quence and Setup push buttons are pressed
simultaneously. The Setup push button and
sequence push button LEDS flash when the
auxiliary menu is displayed.
The upper display indicates “RUNI”. The
lower display indicates “AUTO”, meaning the
factory set automatic run-in speed is se-
lected.
Pushing the Setup push button will step
through the menu. Pushing the sequence
push button will step through the menu in re-
verse.
Pressing the lower display button allows a
manual setting the run-in wire speed. Speed
may be adjusted from 10% to 100% of weld
wire speed.
. The auxiliary menu may be exited at any
time by pressing both the Sequence push
button and the Setup push buttons simul-
taneously.
Pressing the lower display button allows dis-
abling of the run-in feature. When the lower
display indicates “OFF” run-in is disabled.
Process Select
V-Min And V-Max
Process selection indicated by ”PROS” in the
upper display is set to either ”VOLT” or ”TRIM”
in the lower display. Each program can be se-
lected be be a MIG program indicated by
”VOLT” or a pulsing program indicated by
”TRIM”.
Burnback
• If the Setup push button is pressed, the unit
allows the setting of the manual override
power source min and max voltage preset
range. The minimum voltage is displayed in
the upper display and the lower display indi-
cates “VMIN”. When the Setup push button
is pressed the unit displays the maximum
voltage setting of the welding power source.
The maximum voltage is displayed in the up-
per display and the lower display indicates
“VMAX”.
• If the Setup push button is pressed, the unit
allows burnback time to be set.
Burnback time and voltage can be specified
when the lower display indicates “BURN” and
the upper display indicates the burnback time
or voltage. The Adjust control is used to set the
desired burnback time or voltage. Burnback
settings, like run-in settings, are program spe-
cific. The active program is displayed in the
Program display and can be adjusted (see
Range Locks
Range locks are indicated by “LOCK” in the
upper display for wire speed or “LOCK” in the
lower display for voltage range. In a MIG pro-
gram, the voltage range lock ranges from 0 to
10 volts. In a pulse program, the trim range
lock ranges from 0 to 100. The wire feed speed
range lock ranges from 0 to 250 ipm. Locks are
program dependent and wire speed is inde-
pendentfrom voltage or trim.
In both cases, the Adjust control is used to
specify the minimum and maximum voltage
settings of the welding power source. The set-
tings correspond to arc voltage obtained at
minimumcommand and arc voltage obtained
at maximum command.
Trigger Hold Setup
• If the Setup push button is pressed, the unit
allows trigger hold delay time to be set.
Wire Feed Speed Units
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
amountof time the trigger must be held for trig-
ger hold to work when the trigger is released
(the trigger hold function must be on). For ex-
ample, if a trigger hold delay time of 2.0 sec-
onds is defined, the operator must hold the
trigger for at least 2 seconds before releasing
This method of setting “VMIN” and “VMAX”
may be used if the power source being used
is not listed in the Power Source Selection
Menu.
Wire feed speed setting indicated by “WFS” in
the upper display is set to “IPM” inches−per−
minute or ”MPM” meters−per−minute. This
setting is independent of the program se-
lected.
. If a default power source has already been
selected with the Power Source Selection
menu, setting “VMIN” and “VMAX” will
override the default power source set-
tings.
OPT1
• If the Setup push button is pressed, the unit
allows OPT1 to be disabled or enabled.
it in order for the trigger hold function to work. The upper display shows “OPT1”. Lower dis-
Once the trigger hold function is in effect, the play shows “On” or “Off”. The Adjust Control is
wire feeder will stay On until the trigger is
pressed and released again.
. The power source selection menu must
be set to “OFF” when overriding the de-
fault “VMIN” or “VMAX” settings.
used to select either “On” or “Off”.
“OPT1” is used by the Water Flow Shutdown
Power Source Selection Menu
• There is an additional function built in called Option to stop the weld sequence if water flow
”maximum trigger hold time” which is the
maximum length of time the trigger can be set of contacts between pins 1 and 2 of RC26
held and the trigger hold function still work on Interface Board (PC20) will allow feeder to
to a water cooled gun is interrupted. A closed
• If the Setup push button is pressed, the unit
allows the Power Source Selection menu to
be disabled or enabled.
when the trigger is released (the trigger hold operate normally. Opening the contacts will
function must be on). The maximum trigger stop the weld sequence and display “ERR” in
hold time is set at 4.0 seconds after the trig- the upper display and “OPT1” in the lower dis-
ger hold delay time. For example, if a trigger play.
The upper display shows “PSS”. Lower dis-
play shows “On” or “Off”. The Adjust Control is
used to select either “On” or “Off”.
OM-1500-9 Page 23
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6-10 Auxiliary Menus (Continued)
OPT2
hold the last weld information for 5 seconds
must be selected to gain access to the auxilia-
ry menu. A failed attempt return the user to the
weld screen and a counter is incremented. A
counter in the program display shows the
number of incorrect attempts. The user has
five attempts to enter the correct password
code before being locked out of the auxiliary
menu, indicated by “LOCK” in the lower dis-
play . The power may be cycled to continue
welding but the user will remained locked out
of the auxiliary menu. Pressing the Program,
Sequence, upper display, and Set−up push
buttons simultaneously, the counter can be re-
set in the weld screen. 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 will al-
low the user to reset the unit to the factory de-
faults, indicated by “WIPE” in the upper dis-
play. Resetting the unit will also turn off the
password code feature.
following weld termination. If any front panel
push button is pressed, or if the Adjust control
is activated, the display hold feature is termi-
nated.
• If the Setup push button is pressed, the unit
allows OPT2 to be disabled or enabled.
The upper display shows “OPT2”. Lower dis-
play shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
Software Revision Level
• If the Setup push button is pressed, the unit
displays the software version being used by
the interface PCB (PC20).
“OPT2” is a second input that may be used
with an external device, such as a gas flow
switch, to end the weld sequence. The gas
flow switch may be used to stop the weld se-
quence if shielding gas flow to the gun is inter-
rupted. A closed set of contacts between pins
1 and 2 of RC24 on Interface Board (PC20)
will allow feeder to operate normally. Opening
• When the Setup button is pressed again, the
menu repeats.
Code
the contacts will stop the weld sequence and Upon leaving the auxiliary menu, the user is
display “ERR” in the upper display and
“OPT2” in the lower display.
asked if a password code indicated by
“CODE” in the top display should be activated.
By default the code is off, indicated by “OFF”
in the lower display. The user may enter a nu-
Display Hold
Display hold indicated by ”DISP” in the upper merical password between 0 and 999 by turn-
display is set to “OFF” or “HOLD” in the lower ing the Adjust control. When the user re−en-
display. When ”HOLD” is selected, the unit will ters the auxiliary menu, the password code
6-11. Jog/Purge
1
2
3
Jog/Purge Push Button
Adjust Control
Gun Trigger Receptacle
2
3
802 807
1
Pressing the Jog/Purge switch allows the op-
erator to jog wire without energizing the weld
power or gas valve circuit.
trigger is still activated after two minutes, the
jog operation is terminated to prevent com-
plete despooling of the wire, in the case of
a damaged gun.
unit displays jog speed when the unit is be-
ing jogged.
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog opera- • Jog speed can be adjusted by the Adjust
tion for a maximum of two minutes. If the gun control when the unit is jogging wire. The
• The unit displays the “ERR TRIG“ message
to inform the operator that the trigger is acti-
vated.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before weld-
ing and to preset gas pressure at the
regulator.
OM-1500-9 Page 24
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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
gun trigger is released.
Sequence
Parameters
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
Volts
IPM
Seconds
0-9.9
1. Preflow
2. Run-In
3. Start
4. Weld
X
X
X
X
X
X
X
X
0.00-5.00
0-100.0
0-5.00
5. Crater
6. Burnback
7. Postflow
0-0.25
0-9.9
X = Setting available.
Weld Time
Crater
Time
Burnback
Time
Start
Time
Preflow
Time
Postflow
Time
Time
Burnback
Sequence
Postflow
Run-In
Weld
Start
Crater
Preflow
End
Trigger
Released
Trigger
Pressed
OM-1500-9 Page 25
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SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS
8-1. Optional Dual Schedule Switch Diagrams
1
2
Maint 2P (Maintained-Contact
2-Pole Switch)
1
2
Maint 1P (Maintained-Contact
1-Pole Switch)
1
2
DSS-9
1
DSS-8
1
2
2
3
TR
B
A
3
4
A
4
B
SECTION 9 − MAINTENANCE
9-1. Routine Maintenance
Y
Disconnect power before maintaining.
3 Months
Clean and
tighten
Repair or
replace
cracked
weld
Replace
unreadable
labels.
weld
terminals.
cable.
Replace
cracked
parts.
Check
14-pin cord.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
Clean
drive rolls.
Or
monthly.
OM-1500-9 Page 26
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9-2. Diagnostics
1
2
3
4
Wrapper
Motor Control Board PC1
LED3
DIP Switch S1
. There is a two-position DIP
switch S1 located on motor
control board PC1. These
switches are factory-set in the
off position and must remain in
that position for the unit to op-
erate correctly.
2
3
1
4
Front panel is shown removed for purpose of
illustration only. In actual use, front panel
would be in place.
Ref. 802 687
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
ERR
ERR
OPT1
ERR
COM1
TRG1
TCH1
MTR1
OPT2
Indicates a
communication
error.
Indicates a trigger
error.
Indicates a
tachometer error.
Indicates a motor
error.
No gas flow
detected.
Optional error
condition.
LED3-RelatedError Indications
4 blinks = Motor Error
speed is regulated through the monitoring of
voltage and current.
Error conditions are indicated by LED3 on
PC1. To view LED3, turn Off unit, remove
wrapper, and turn unit On. LED3 is most easily
observed from the left side of the unit.
The LED blinks in a 2.5 second cycle. The
number of blinks in this period indicates the
type of error.
ERR COM1
ERR MTR1
• The communication error occurs 2.5 sec-
onds after a loss of communication between • The motor error indicates that the motor
the motor and front panel boards. The user
may continue to weld with this error. The er-
ror may be cleared by resetting the unit (see
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle.
The 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.
ERR TRG1
ERR OPT1
• The trigger error occurs if the user has the • The optional 1 error indicates no coolant
trigger held for more than two minutes with-
out striking an arc, 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.
flow in water flow switch option. The error
may be reset by reestablishing coolant flow
to the gun, and then pressing any button on
front panel.
ERR OPT2
• The optional 2 error indicates a problem
with optional device connected to RC24 on
Interface Board (PC20). The error may be
reset by correcting the problem, and then
pressing any button on front panel.
ERR TCH1
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
OM-1500-9 Page 27
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Notes
OM-1500-9 Page 29
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Item
No.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 159 647 . . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 159 646 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 159 360 . . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . Figure 11-3 . . Drive Assembly, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 141 753 . . Hub & Spindle Assembly, (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 180 571 . . . . 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 1.500dia X .125thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . 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 . . . . . . . . . . . . . . . 135 205 . . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 200 556 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 201 781 . . Knob, W/Extension Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 156 243 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 145 639 . . Strip, Buna N Compressed Sheet .062 X 4.000 X 4.000 . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 200 552 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 134 306 . . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . . 200 557 . . Stiffener, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . Figure 11-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1500-9 Page 31
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. Hardware is common and
not available unless listed.
1
4
8
9
10 11
3
13
10 12
11
2
23
7
24
14
5
6
18
22
19
15
20
21
17
802 802-D
Figure 11-2. Control Box
Item
No.
Diagram
marking
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 200 555 . . Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 200 153 . . Overlay, Upper Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 204 762 . . Overlay, Upper Front Panel (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . PC21 . . . . . 200 693 . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . PC20 . . . . . 210 559 . . Panel, PC Card Display/Micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 200 551 . . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 134 201 . . Stand-Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 7 . . . . . . . . . . . . . . . 200 554 . . Enclosure, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 494 . . Bushing, Snap-In Nyl 1.375 Id X 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 357 . . Bushing, Snap-In Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 204 910 . . Cable, Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 163 519 . . . . Cable, Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Ft
. . . 11 . . . . . . . . . . . . . . . 139 041 . . . . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 079 739 . . . . Conn, Circ Cpc Clamp Str Rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . PLG12 . . . . 141 162 . . . . Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . . 115 093 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 605 227 . . Nut, 750-14 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . GS1 . . . . . 228 035 . . Valve, 34VDC 1Way .750−14 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC1 . . . . . 217 872 . . Circuit Card Assy, Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC1 . . . . . 217 922 . . Circuit Card Assy, Motor Control (Low Speed Motor) . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . S1 . . . . . . 111 997 . . Switch, Rocker Spst 10a 250 VAC On-Off . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 200 559 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-1500-9 Page 32
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Item
No.
Diagram
marking
Part
No.
Description
Quantity
. . . 20 . . . . . S2 . . . . . . 200 295 . . Switch, Rocker Spdt 15a 12v (On)-Off-(On) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 207 741 . . Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 207 740 . . Nameplate, (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 213 134 . . Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . 1
. . . 23 . . . . RC13 . . . . . 048 282 . . Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . . 115 094 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG11,61 . . . 131 005 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . . 202 592 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . 136 810 . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG7,27 . . . 115 091 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . . 130 203 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 134 646 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 936 . . Label, Warning General Precautionary Wordless CE . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 211 989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-1500-9 Page 33
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13
. Hardware is common and
19
not available unless listed.
11
14
15
16
See Table 11-1 For
Drive Roll & Wire Guide Kits
17
18
9
7
8
6
5
4
3
19
2
12
20
1
10
11
21
22
37
23
24
25
26
36
35
34
27
33
28
6
32
31
29
5
30
4
3
2
1
803 790-A
Figure 11-3. Drive Assembly, Wire
Item
No.
Diagram
marking
Part
No.
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 . . . . . . 201 230 . . Motor, Gear 1/8Hp 24VDC Standard Speed . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . M1 . . . . . . 201 231 . . Motor, Gear 1/8Hp 24VDC High Speed (Optional) . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . M1 . . . . . . 209 131 . . Motor, Gear 1/8Hp 24VDC Low Speed (Optional) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 491 . . . . Kit, Brush Replacement (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 550 . . . . Cover, Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
. . . . . . . . . . . . . . . . . . . . . 203 631 . . Pressure Arm, S/L & Vert S/R 4 Roll (Consisting Of) . . . . . . . . . . . . . . . . . 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
OM-1500-9 Page 34
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Item
No.
Diagram
marking
Part
No.
Description
Quantity
. . . 15 . . . . . . . . . . . . . . . 182 155 . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . 132 746 . . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . . 203 633 . . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 203 632 . . . . Carrier, Shaft Dual Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . 201 225 . . Circuit Card, Digital Tach (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . . . 2Ft
. . . 27 . . . . . . . . . . . . . . . 149 959 . . Fitting, Brs Barbed M 3/16tbg X .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 179 265 . . Adapter, Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 196 956 . . . . 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-1500-9 Page 35
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G u i d e
I n t e r m e d i a t e
I n l e t G u i d e
OM-1500-9 Page 36
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
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Effective January 1, 2006
(Equipment with a serial number preface of “LG” 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:
Service
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.)
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 date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
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.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
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.
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.
*
(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
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
*
*
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2006−01
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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
© 2006 Miller Electric Mfg. Co.2006−01
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