Miller Electric Welder 394F User Manual

OM-222 394F  
Processes  
200608  
MIG (GMAW) Welding  
Flux Cored (FCAW) Welding  
(Gas- And Self-Shielded)  
Description  
Wire Feeder  
Axcess Dual  
Wire Feeder  
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TABLE OF CONTENTS  
WARRANTY  
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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING  
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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.  
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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  
the Safety Standards listed in Section 1-5. Read and follow all  
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.  
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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.  
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Turn Off inverter, disconnect input power, and discharge input  
capacitors according to instructions in Maintenance Section  
before touching any parts.  
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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.  
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Disconnect input power or stop engine before installing or  
servicing this equipment. Lockout/tagout input power according to  
OSHA 29 CFR 1910.147 (see Safety Standards).  
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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-222 394 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.  
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Wear an approved welding helmet fitted with a proper shade of fil-  
ter lenses to protect your face and eyes when welding or watching  
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).  
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.  
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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.  
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
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.  
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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.  
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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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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.  
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High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
Have only qualified persons familiar with  
electronic equipment perform this installation.  
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:  
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Engine exhaust contains chemicals known to the State of  
California to cause cancer, birth defects, or other reproductive  
harm.  
For Diesel Engines:  
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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.  
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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-222 394 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:  
8004636727 or in Toronto 4167474044, website: www.csain-  
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 100368002 (phone: 2126424900,  
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 022699101 (phone:  
6177703000,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  
022699101(phone: 6177703000, 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 222024102 (phone: 7034120900, 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  
3123532220,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  
committees judgment, has not demonstrated that exposure to power-  
frequency electric and magnetic fields is a human-health hazard.”  
However, studies are still going forth and evidence continues to be  
examined.Until the final conclusions of the research are reached, you  
may wish to minimize your exposure to electromagnetic fields when  
welding or cutting.  
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-222 394 Page 4  
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SECTION 2 CONSIGNES DE SÉCURITÉ LIRE AVANT UTILISATION  
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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.  
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Indique un message de sécurité particulier  
. Signifie NOTE ; n’est pas relatif à la sécurité.  
2-2. Dangers relatifs au soudage à l’arc  
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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  
dans les normes de sécurité énumérées dans la Section 2-5. Lire et  
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.  
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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.  
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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  
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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.  
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Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à  
une même borne de sortie de soudage.  
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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.  
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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.  
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LES FUMÉES ET LES GAZ peuvent  
être dangereux.  
Le soudage génère des fumées et des gaz. Leur  
inhalationpeut être dangereuse pour la santé.  
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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.  
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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 pDas souder des métaux munis d’un revêtement, tels que l’acier  
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-  
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit bien  
ventilé et en portant un respirateur à alimentation d’air.  
Les revêtements et tous les métaux renfermant ces éléments  
peuvent dégager des fumées toxiques en cas de soudage.  
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-222 394 Page 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-222 394 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-222 394 Page 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-222 394 Page 8  
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SECTION 3 INTRODUCTION  
3-1. Specifications  
Type of Input  
Power  
Welding Power  
Source Type  
Wire Diameter  
Range  
Welding Circuit  
Rating  
Overall  
Dimensions  
Wire Feed Speed Range  
Weight  
40 Volts DC  
10 Amperes  
Axcess Series  
Standard: 40 To 1400 ipm (1.0  
To 35.6 mpm)  
.030 To 1/8 in  
100 Volts,  
750 Amperes,  
100% Duty  
Cycle  
Length: 27 in (686  
mm)  
87 lb  
(39.5 kg)  
(0.8 To 3.2 mm)  
Width: 12-1/2 in  
(318 mm)  
Max Spool  
Weight: 60 lb (27  
kg)  
Height: 14-1/2 in  
(368 mm)  
SECTION 4 INSTALLATION  
4-1. Selecting A Location  
Y
Do not move or operate  
unit where it could tip.  
Movement  
Tipping  
2
OR  
1
Location  
Y
Do not stack units. Beware of  
tipping.  
Y
Special installation may be required where gasoline or volatile  
liquids are present see NEC Article 511 or CEC Section 20.  
1
Lifting Forks  
Use lifting forks to move unit.  
4
Extend forks beyond opposite side  
of unit.  
2
Hand Cart  
Use cart or similar device to move  
unit.  
3
Rating Label  
3
Use rating label to determine input  
power needs.  
18 in  
(460 mm)  
4
Line Disconnect Device  
Locate unit near correct input  
power supply.  
18 in  
(460 mm)  
loc_2 3/96 - 804 018-A  
OM-222 394 Page 9  
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4-2. Connection Diagram  
1
2
3
4
5
6
7
8
Welding Power Source  
Wire Feeder  
Gas Cylinder  
Gas Hose  
3
Network Feeder Cable  
Negative () Weld Cable  
Workpiece  
Voltage Sensing Lead  
Recommendedfor Accu-pulse and  
RMD (optional).  
. Positive (+) voltage sensing  
lead is contained in the motor  
cable.  
4
5
9
Positive (+) Weld Cable  
2
1
9
7
6
8
804 019-A  
OM-222 394 Page 10  
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4-3. Rear Panel Connections And Rotating Drive Assembly  
1
2
3
9-Pin Network Receptacle  
Power Switch  
Shielding Gas Valve Fitting  
(Left And Right)  
Requires fitting with 5/8-18 right-  
hand threads. Connect customer-  
supplied gas hose.  
3
4
5
6
7
8
Weld Cable Terminal  
Jumper Cable  
2
1
Weld Cable  
Drive Assembly  
9
Drive Assembly Rotation  
Knob (Left And Right)  
9
Rating Label Location  
To rotate the drive assembly,  
loosen drive assembly rotation  
knob, rotate drive assembly, and  
tighten knob.  
4
5
6
7
8
Tools Needed:  
9/16, 5/8 in  
804 020-A / 802 825-A  
OM-222 394 Page 11  
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4-4. 9-Pin Network Receptacle Information  
Pin  
Pin Information  
9
A
B
C
D
E
F
Capacitor C1 to ground  
Shield  
Volt sense  
F
I
G
Can low  
E
H
Can high  
D
A
+24 volts dc common  
+ 24 volts dc  
C
B
G
H
Motor voltage +40 volts dc common  
I
Motor voltage +40 volts dc  
4-5. Gun Recommendation Table  
Process  
Gun  
GMAW Hard or Cored Wires  
400, 500, And 600 Amp  
Air-Cooled Guns  
GMAW Pulse  
Water-Cooled Guns  
OM-222 394 Page 12  
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4-6. 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. Once wire  
has reached the liner, auto-thread wire by  
momentarily pressing Purge and quickly  
pressing Jog to begin auto-threading wire.  
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A  
OM-222 394 Page 13  
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4-7. Power Source Display At Power Up  
1
2
Upper Display  
Lower Display  
1
Program  
Volts  
WFS  
Time  
Arc Length  
Arc Ctl  
Amps  
2
Sequence  
Process  
Trigger Control  
Trigger Hold  
Wire Type  
Gas Type  
Process Set Up  
Adjust  
Feeder Set Up  
Upper Display  
Net  
Voltage Range  
Power Source  
Lower Display  
Wait  
OFF  
DTEC  
Axcess  
Axcs  
300/450/675  
10  
44  
4-8. Dual Schedule Switch Option  
1
Maint 2P (Maintained-Contact  
2-Pole Switch)  
DSS-9M Part# 041 793  
1
2
DSS-9M 1  
2
1
A
B
3
4
OM-222 394 Page 14  
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SECTION 5 OPERATION  
5-1. Operational Terms  
The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:  
General Terms:  
Arc Adjust  
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases  
the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by  
volts in MIG programs.  
Trigger Control  
Selecting Trigger Control allows activating trigger functions such as DS, TH, 4T, TDS, and TPS.  
Dual Schedule allows selecting a pair of programs that can be used together.  
DS (Dual Schedule)  
TH (Trigger Hold)  
Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger  
hold mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed  
again.  
4T  
4T allows the operator to select between weld parameters and crater parameters using the gun  
trigger. Crater time must be set for at least 0.2 seconds to make this function operational. If gun  
trigger is released during welding, unit goes into trigger hold, then pressing and holding trigger again  
causes unit to stay in crater until trigger is released and crater parameter times out.  
TDS (Trigger Dual Schedule)  
TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS  
mode, momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected  
weld programs.  
TPS (Trigger Program Schedule)  
TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily  
pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total  
of 8 programs.  
Program  
Process  
MIG  
Eight active slots for selection of various processes, wire type, and parameters.  
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).  
CV weld process with individual settings of voltage and wire speed.  
Pulse  
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as  
factory taught data. Adaptive method is controlled by frequency adjustment.  
Accu-pulse  
Pulse process utilizing constant current ramps with constant voltage control of peaks and  
backgrounds. Adaptive response is controlled by peak and minimum current levels. Benefits are  
shorter arc lengths, better puddle control, more tolerant of tip-to-work variation, less audible noise, no  
arc wandering, allows weld to fill in at toes increasing travel speed and deposition, and more tolerant  
to poor fit up and gaps.  
Accuspeed  
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is de-  
signed to be tight and fast. Front panel display is ACCU SPED.  
AccuCurve  
CV Pulse process using a pulse waveform with modified curves at particular locations within the wa-  
veform. Has a distinguished change in arc characteristics. Front panel display is ACCU CURV.  
RMD (optional)  
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of  
RMD are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat  
input into workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge  
materials.  
Wire Type  
Gas Type  
Selection of wire type by alloys and classification.  
Selection of shielding gas being used in application.  
Selection procedure for entering program.  
Process Set Up  
Program Load  
Volts  
Enters selected program information into program slot.  
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of  
weld.  
Time  
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in  
the Arc On and Analog input or the Arc On and No Analog input modes).  
Arc Length  
WFS  
Distance from end of wire electrode to workpiece.  
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage  
setting. In pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power  
level on wire electrode (one knob control).  
Amps  
Indicates average amperage while welding and 3 seconds hold value at end of weld.  
Arc Control  
Allows setting of inductance in MIG mode. In pulse and Accu-pulse mode, this adjustment changes  
the arc cone by adjusting the preprogrammed factory pulse data. In RMD (optional), this control will  
affect the in much the same way as inductance.  
Inductance  
Adjust  
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit  
transfers per second (provided no other changes are made) and increase the arc-on time. The  
increased arc-on time makes the welding puddle more fluid.  
Control knob used to change or set parameters and functions.  
OM-222 394 Page 15  
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General Terms:  
Sequence  
Preflow  
Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters.  
Setting a time value for gas flow prior to arc start.  
Start  
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only  
adjustable with the optional PDA with File Management/WaveWriter software).  
Crater  
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.  
Setting a time value for gas flow after arc end.  
Postflow  
Feeder Set Up  
Auto Thread  
Allow selection of Sequence and trigger functions.  
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously  
will automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be  
changed using a PDA with File Management/WaveWriter software). Pressing jog, purge, or trigger  
switch will terminate the auto-threading feature.  
OM-222 394 Page 16  
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SECTION 6 OPERATION  
6-1. Power Switch  
1
Power Switch  
1
804 021-A  
6-2. Left/Right Select Switch  
1
Left/Right Select Switch  
Pressing the Left/Right Select  
switch allows the operator to  
choose which side of the units’ con-  
trols will operate.  
1
. Depressing the Left or Right  
Gun Trigger also allows the  
operator to enable the con-  
trols on that side of the unit.  
804 022-A  
OM-222 394 Page 17  
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6-3. Jog/Purge  
1
2
3
Jog/Purge Push Button  
Gun Trigger Receptacle  
Adjust Knob  
3
2
804 022-A  
1
The Jog/Purge switch provides the following  
functions:  
ent as indicated on feeder upper display. Af-  
ter 3 seconds the weld output turns off and  
the wire will feed at 60 ipm for the next 3 sec-  
onds and then ramps up to 700 ipm until trig-  
ger is released or 30 seconds elapses. If the  
gun trigger is still activated after 30  
seconds, the jog operation is terminated to  
prevent complete unspooling of the wire and  
an “ERR STRT” message is displayed on  
the upper and lower displays. Releasing  
and pressing the trigger again will clear the  
error.  
the first 3 seconds of run in and jogging  
from the trigger is not possible.  
Pressing left side of the Jog/Purge switch  
allows the operator to feed wire without  
energizing the weld power or gas valve  
circuit. The wire will feed at a 60 ipm rate for  
3 seconds, then the rate ramps up to 700  
ipm until the Jog switch is released.  
Pressing right side of the Jog/Purge switch  
allows the operator to purge gas lines before  
welding and to preset gas pressure at the  
regulator.  
This unit is equipped with Auto Thread  
capability. By rocking the switch from purge  
to jog within 0.5 seconds will automatically  
feed wire for a factory default setting of 192  
in (4877 mm) of wire before stopping. The  
default feed rate is 700 ipm. These settings  
can be changed using an optional PDA with  
File Management/WaveWriter software.  
The unit also provides the ability to jog the  
wire feeder by means of the gun trigger.  
When the gun trigger is pressed without  
starting an arc, the wire will feed at run-in  
speed for the first 3 seconds. During this  
time OCV (open circuit voltage) will be pres-  
. If Start Error is enabled using an optional  
PDA with File Management/WaveWriter  
software, an “ERR STRT” will occur after  
OM-222 394 Page 18  
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6-4. Front Panel Sections  
See  
Section  
See  
Section  
See  
Section  
Program  
Volts  
WFS  
Time  
Arc Adjust  
Arc Ctl  
Amps  
Sequence  
Process  
Trigger Control  
Trigger Hold  
Wire Type  
Gas Type  
Process Set Up  
Adjust  
Feeder Set Up  
See  
Section  
See  
Section  
See  
Section  
OM-222 394 Page 19  
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6-5. Program Push Button  
1
Program Display  
The number of the active program  
is displayed.  
2
3
Program Push Button  
Program Push Button LED  
The LED lights to indicate that  
programs can be changed using  
the Adjust knob.  
1
2
Momentarily press button to  
illuminate LED. To change the  
program number, rotate Adjust knob  
to select one of eight programs.  
3
Program  
Pressing and holding the push  
button will display the program  
name, current wire size, wire type,  
and process.  
To retrieve the original eight factory  
default programs, press and hold  
button in on power up. Top display  
will show RST, bottom display will  
show NO, and Feeder Set Up  
button LED will be flashing. Turn  
Adjust control to change bottom  
display to show YES, then press  
Feeder Set Up button to confirm  
selection. Continue by allowing  
feeder to proceed with power up.  
6-6. Upper Display  
3
2
1
4
Volts  
Arc Adjust  
5
1
Upper Display  
illuminates to indicate that information  
displayedcan be changed by the Adjust knob.  
Adjust knob. The preset values will be  
displayed while the knob is being rotated  
and return to displaying actual values  
when adjustment is completed.  
The upper display at idle (not welding) shows  
preset volts with process selection MIG or Arc  
Adjust for all other processes. When welding,  
the display shows actual voltage. The display  
will show actual voltage for approximately 3  
seconds after welding stops before returning  
to preset value.  
4
Volts LED  
Indicates a voltage value is being displayed,  
preset voltage in MIG when not welding and  
actual voltage while welding.  
To activate Carbon Arc Gouging (CAC), press  
and hold the upper display push button in on  
power up. CAC will appear on the upper dis-  
play and NO will appear on the lower display.  
Rotate adjust knob to YES on the lower dis-  
play, and press the flashing Feeder Set up  
push button . CYCL will appear on the upper  
display and PWR will appear on the lower dis-  
play. Turn welding power source off and back  
5
Arc Adjust LED  
Indicates that displayed value is an arc length  
value when the process is Pulse, Accu-pulse,  
or RMD (optional).  
2
Upper Display Push Button  
Press the button to illuminate the LED and  
allow changing information in the display.  
. At any time while welding, the display  
3
Upper Display Push Button LED  
allows adjustment of the weld voltage or on again to enable the Carbon Arc Gouging  
The upper display push button LED  
arc adjust preset values by turning the process selection.  
OM-222 394 Page 20  
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6-7. Lower Display  
5
7
6
Time  
1
2
WFS  
Amps  
Arc Ctl  
3
4
1
Lower Display  
4
Arc Ctl (Arc Control) LED  
When the lower display push-button LED and  
the WFS LED are both illuminated, it is  
possible to change WFS while welding by  
using the Adjust knob. The value in the display  
will switch momentarily to show preset wire  
feed speed while turning the Adjust knob and  
revert back to actual value when adjustment is  
completed.  
LED illuminates to indicate that inductance  
(MIG) or ARC [Pulse, Accu-pulse, or RMD  
(optional)]is being displayed and can be ad-  
justed using the Adjust knob.  
The lower display shows WFS (wire feed  
speed), AMPS (amperage), ARC CTL (arc  
control), or Time. The feeder displays only  
preset wire speed at idle (not welding). While  
welding, the average amperage is displayed.  
The lower display shows welding sequence  
time when the Time LED is illuminated.  
5
Time LED  
LED illuminates to indicate that a time value is  
being displayed for a sequence function and  
can be adjusted using the Adjust knob.  
6
7
Pressing the button illuminates the LED and  
selects either WFS or Arc Ctl value for  
changing using the Adjust knob.  
To select Arc Ctl, press and hold lower display  
button for 2 seconds. The top display will show  
either INDU for a MIG program or ARC for  
Pulse, Accu-pulse, or RMD (optional). To exit  
When the Arc Ctl LED is illuminated, it is pos-  
sible to change values while welding by using  
the Adjust knob. To return to actual values on  
the display, exit the Arc Ctl display.  
2
WFS (Wire Feed Speed) LED  
Lower Display Push Button  
Lower Display Push Button LED  
LED illuminates to indicate the preset wire feed  
value is being displayed and can be adjusted  
using the Adjust knob.  
. The lower display push button has addi-  
tional functions when entering the se-  
quence and trigger control functions (see  
3
Amps LED  
LED illuminates to indicate the average  
amperage is being displayed while welding  
and for 3 seconds after welding is terminated. Arc Ctl or INDU, either press the upper display  
The amperage must be above a minimum  
value of 25 amps for this function to operate.  
push button or press and hold the lower display  
push button for 2 seconds.  
OM-222 394 Page 21  
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6-8. Feeder Set Up Push Button  
3
4
Sequence  
Start  
Time  
Crater  
Time  
Trigger Control  
Trigger Hold  
1
Preflow  
Time  
Postflow  
Time  
2
Sequence Diagram  
Feeder Set Up  
1
2
Feeder Set Up Push Button LED  
Feeder Set Up Push Button  
the Upper Display push button.  
ger control selections. Use the Adjust knob  
to cycle through the trigger control methods  
as follows: DS, TH, TDS, TPS, and 4T (see  
Section 5-1 for definitions). The lower dis-  
play will show the current state of each trig-  
ger control method as being on or off. Not all  
trigger control methods are compatible with  
each other, therefore, turning on certain trig-  
ger selections will cause other trigger selec-  
tions to turn off.  
The Sequence option STRT and CRTR will  
have additional parameter settings. By  
pushing the Lower Display push button a  
second time, while STRT or CRTR appear  
in the upper display, allows entering voltage  
(MIG) or Arc Adjust [Pulse, Accu-pulse, or  
RMD (optional)]. Use the Adjust knob to  
change the values indicated by the flashing  
LED for either Volts or Arc Adjust. Pressing  
the Lower Display push button a third time  
will activate the WFS setting for either STRT  
or CRTR and the WFS LED will begin flash-  
ing. Use the Adjust knob to change the WFS  
value.  
Press button to choose Sequence. Feeder  
Set Up push-button LED will illuminate.  
3
Sequence LED  
When the Feeder Set Up button is pressed  
once, the Sequence LED will illuminate and  
the upper display will show sequence  
options. Use the Adjust knob to select PRE  
(preflow), STRT (start), CRTR (crater), or  
POST (postflow).  
Press the lower display push button to illu-  
minatethe push-button LED and enable the  
use of the Adjust knob to allow turning se-  
lected trigger control methods on or off. If  
trigger hold is set to on, the Trigger Hold  
LED will illuminate.  
Press the lower display push button and the  
Lower Display push-button LED will  
illuminateas well as the lower display. The  
Time LED will automatically begin flashing  
indicating that a time value can be entered  
by turning the Adjust knob. By entering a  
time value the sequence state will become  
Pressing the Feeder Set Up button two  
more times will exit the Sequence menu and  
return the system to standby mode.  
. Trigger Hold is automatically set to On  
with the 4T trigger selection. This is part  
of the 4T function.  
4
Trigger Control LED  
active. To turn off a sequence state, change Press the Feeder Set Up button twice and  
the time value to OFF. To step back for  
selecting another sequence option, press  
the Trigger Control LED will illuminate, and Press the Feeder Set Up button a third time  
the upper display will show the different trig-  
to cycle back to standby mode.  
6-9. Adjust Knob  
1
Adjust Knob  
The Adjust knob is used to change  
functions and parameters. Refer to  
the front panel sections for  
information regarding use of this  
control.  
1
Adjust  
OM-222 394 Page 22  
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6-10. Process Set Up Push Button  
1
2
3
Process Set Up Push Button  
Process Set Up LED  
Process  
Wire Type  
Gas Type  
3
Program Selection LEDs  
2
1
Process Set Up  
Press the Process Set Up push button the Pressing the Process Set Up push button a If a custom program is loaded using an  
first time will illuminate the button LED and  
the Process LED. The upper and lower  
displays will be used for Accu-pulse and  
only the lower display for MIG, Pulse and  
RMD (optional) to show the current process  
installed in this program. To change  
process, turn the adjust knob.  
fourth time will keep Wire Type LED lit and  
the upper display will show wire size. The  
upper display push button will be flashing  
indicating that turning the Adjust knob will  
select wire sizes available for that particular  
process and wire type.  
Pressing the Process Set Up push button a  
fifth time will illuminate the Gas Type LED  
and the lower display will show GAS and the  
upper display will show gas selection (see  
Table 6-1 for gas abbreviations). To make a  
gas type selection, turn the Adjust knob.  
If any of the Process, wire type, alloy type,  
wire size, or gas type was changed, then  
pressing the Process Set Up push button a  
sixth time will show PROG in the upper  
display and LOAD in the lower display. The  
new program would be loaded for that  
particular program in slot 1 thru 8. If no  
changes were made to any setup items, no  
program will be loaded, and unit will return  
to standby mode.  
optional PDA with File Management/Wa-  
veWriter software, the Program Display will  
have a “C” in front of the program number.  
This indicates that the program is not a  
factory default program and has been  
modified. By selecting or changing any  
process variable and performing a program  
load will restore the program back to the  
factory default program.  
Pressing the Process Set Up push button a  
second time will illuminate the Wire Type  
LED and the lower display will show wire  
types available for selected processes (see  
selection, turn the Adjust knob.  
Pressing and holding the Process Set Up  
push button in on power up allows viewing  
the software revisions of each circuit board  
in the system. The top display shows the  
board (PCM, UIM, WFCM, and AIM (auto-  
mated units only) and the lower display  
shows the last 3 digits of the circuit board  
part number plus a letter designator. Press  
the flashing Feeder Set Up push button to  
exit the screen displays and continue the  
power up process.  
Pressing the Process Set Up push button a  
third time will keep Wire Type LED lit and the  
upper display will show wire alloy type (see  
Table 6-1 for alloy types). The upper display  
push-buttonLED will be flashing indicating  
that turning the Adjust knob will change the  
alloy type for the selected process and wire  
type.  
Table 6-1. Welding Wire And Gas Abbreviations*  
Wire Description Wire Abbreviation  
Alloy Type  
Gas Type  
100% CO ,  
Gas Abbreviation  
Steel  
STL  
E70, E100, E120  
CO2  
C10  
C15  
C25  
C5  
OX5  
OX2  
2
90% Argon/10% CO ,  
2
2
2
2
85% Argon/15% CO ,  
75% Argon/25% CO ,  
95% Argon/5% CO ,  
95% Argon /5% O ,  
2
2
98% Argon/2% O  
Stainless Steel  
SS  
308, 309, 312, 316  
98% Argon, 2% O  
OX2  
2
(81Ar/18HE/1CO  
Accu-pulse)  
Tri Gas  
2
90HE/7-1/2Ar/2-1/2CO  
MIG/RMD)  
Tri Gas  
2
Cored Tubular Wire  
Aluminum  
MCOR  
ALUM  
71, 76, 86R, 409  
4XXX, 5XXX  
90% Argon/10% CO  
C10  
OX2  
2
98% Argon/2% O  
100% Argon  
2
ARGN  
* Not all wire types may be available with your unit.  
OM-222 394 Page 23  
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6-11. Reset Mode  
. Reset mode is not active when  
Program Lock is enabled.  
RST  
NO  
The reset mode allows the operator to  
reload factory program settings for all  
eight active programs in the unit.  
. System configuration data will be  
lost during the Reset operation.  
Enter reset mode by turning power On and pressing  
the Program Push Button until the RST NO message  
is displayed. RST NO message will not display until  
after the power-up sequence is completed  
(approximately 20 seconds).  
RST  
YES  
RST  
YES  
CYCL  
PWR  
Press the Arc Control button to  
confirm the reset.  
Cycl Pwr message appears on the display  
when programs complete loading.  
Rotate Adjust knob to change NO  
to YES.  
The reset message is displayed for  
2 seconds while factory program  
settings are being reloaded.  
Turn power off, wait 10 seconds, and turn  
power back on again to complete the reset  
operation.  
During the reset mode the following  
factory default programs are loaded  
into the unit:  
. After Reset is complete, be sure to load  
appropriate programs that contain the  
correct wire size, process, and shielding gas  
for the welding operation  
Program 1  
Program 2  
Program 3  
Program 4  
Program 5  
Program 6  
Program 7  
Program 8  
Pulse  
.035 Mild Steel  
90% Argon, 10% CO  
2
MIG  
.035 Mild Steel  
75% Argon, 25% CO  
2
Accu-pulse  
.035 Mild Steel  
90% Argon, 10% O2  
Pulse  
.045 Mild Steel  
90% Argon, 10% CO  
2
MIG  
.045 Mild Steel  
75% Argon, 25% CO  
2
Accu-pulse  
.045 Mild Steel  
90% Argon, 10% O2  
Pulse  
.052 Mild Steel  
90% Argon, 10% CO  
2
MIG  
.052 Mild Steel  
75% Argon, 25% CO  
2
198 993 / 803 246-B  
OM-222 394 Page 24  
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SECTION 7 SETTING SEQUENCE PARAMETERS  
7-1. Sequence Parameters In A Program  
. For more information on  
Sequence mode, see Feeder  
Set Up Push Button in Section  
6-8.  
Weld Time can only be set by using  
an optional PDA with File  
Management/WaveWriter software.  
Sequence  
Parameters  
Volts/Arc  
Adjust  
If time is set to zero in any timed  
sequence, the sequence is skipped.  
IPM  
Seconds  
Off-5.0  
. Maximum IPM may actually be  
lower depending on the process  
and wire type selection.  
1. Preflow  
2. Postflow  
3. Start  
Off-5.0  
Off-5.0  
10.0-44.0/  
0-99  
40-1400  
40-1400  
10.0-44.0/  
0-99  
4. Crater  
Off-5.0  
Weld  
Crater  
Time  
Start  
Time  
Preflow  
Time  
Postflow  
Time  
Sequence  
End  
Weld  
Start  
Crater  
Postflow  
Preflow  
Trigger  
Released  
Trigger  
Pressed  
OM-222 394 Page 25  
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SECTION 8 MAINTENANCE  
8-1. Routine Maintenance  
Y
Disconnect power  
before maintaining.  
. Maintain more often  
during severe conditions.  
n = Check  
Z = Change  
~ = Clean  
l = Replace  
Reference  
* To be done by Factory Authorized Service Agent  
Every  
3
Months  
l Unreadable Labels  
~ Weld Terminals  
l Damaged Gas Hose  
nl Weld Cables  
nl Cords  
nl Gun Cables  
OR  
nl Cracked Parts  
Every  
6
Months  
~ Drive Rolls  
~ Inside Unit  
OM-222 394 Page 26  
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8-2. Diagnostics  
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  
WFS  
ERR  
ERR  
ERR  
TACH  
MOTR  
STRT  
STOP  
FLOW  
Indicates a  
tachometer error.  
Indicates a motor  
error.  
Indicates a wire  
feed speed error.  
Indicates an arc  
start error.  
Indicates an arc  
stop error.  
Indicates a gas  
flow error.  
ERR  
ERR  
GND  
ERR  
ERR  
ERR  
ERR  
ARC  
COOL  
STUK  
TEMP  
LINE  
Indicates a coolant  
flow error.  
Indicates a ground  
current error.  
Indicates a wire  
stuck error.  
Indicates a  
temperature error.  
Indicates a line  
error.  
Indicates an arc  
error.  
ERR TACH  
ERR STOP  
ERR STUK  
The tach error occurs 2 seconds after the The stop error occurs as result of The stuck error occurs if the welding wire  
loss of tachometer feedback. The motor  
speed is regulated through the monitoring of  
voltage and current. Press Jog/Purge  
button to clear error.  
obstructions in the wire feed system or a  
faulty wire drive system. Check wire feed  
and wire drive systems. Press Jog/Purge  
button to clear error.  
sticks to the workpiece at the end of a weld.  
May be caused by poor weld conditions.  
The error may be cleared by cutting wire  
from workpiece, and pressing the Jog/  
Purge button.  
ERR MOTR  
ERR FLOW  
ERR TEMP  
The motor error indicates that the motor  
has been drawing too much current for too  
long. To remedy this, reduce the wire feed  
speed or the wire feeder torque load/duty  
cycle. Press Jog/Purge button to clear error.  
The flow error indicates no gas flow to the  
gun. The error may be reset by The temperature error indicates welding  
reestablishinggas flow to the gun, and then  
pressing the Jog/Purge button.  
power source has overheated and  
shutdown. The error may be cleared by  
allowingunit to cool down, and pressing the  
Jog/Purge button.  
ERR COOL  
The cool error indicates no coolant flow in  
water flow switch option. The error may be  
reset by reestablishing coolant flow to the The line error indicates input power is  
gun, and then pressing the Jog/Purge  
button.  
ERR WFS  
ERR LINE  
The wire feed speed error indicates actual  
wire feed speed does not match wire feed  
speed command. Press Jog/Purge button  
to clear error.  
outside of unit operating range. Check and  
correct input power. Press Jog/Purge  
button to clear error.  
ERR STRT  
ERR GND  
ERR ARC  
The start error occurs if the user has the  
trigger held for more than 3 seconds without  
striking an arc, or if a valid arc voltage and  
current is not detected. The 3 second arc  
start error time can be changed using an op-  
tional PDA with File Management software.  
The ground current error occurs if weld  
current is detected in the earth ground The arc error indicates an arc outage  
connection. May be caused by a conductor  
making contact with unit chassis. Check  
and repair feeder weld connections. Press  
Jog/Purge button to clear error.  
occurred possibly from a wire feeder error  
or power source error. Check wire feeder  
and power source. Press Jog/Purge button  
to clear error.  
OM-222 394 Page 27  
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8-2. Diagnostics (Continued)  
WELD  
WAIT  
MOTR  
PLS  
OVER  
CRNT  
LOW  
WFS  
E
COM  
WAIT  
STOP  
Indicates an  
emergency stop error.  
Indicates a weld  
cycle wait error.  
Indicates a motor  
Indicates a UIM  
Indicates an  
overcurrent error.  
Indicates a low WFS  
command error.  
communication error. communication error.  
RMD  
OVER  
AVER  
REL  
ERR  
DONE  
TRIG  
UNKN  
Indicates an arc  
error.  
Indicates an over  
average current error.  
Indicates a trigger  
closed error.  
Indicates an  
unknown error.  
WELD WAIT  
LOW WFS  
OVER AVER  
The weld wait error indicates unit was not  
ready for a weld sequence. Press Jog/  
Purge button to clear error.  
The low wire feed speed error indicates  
actual wire feed speed is lower than wire  
feed speed command. Check for  
obstructions in the wire feed system or a  
faulty wire drive system. Press Jog/Purge  
button to clear error.  
The over average error indicates that cur-  
rent is outside the average range for the set  
program parameters. Check and correct  
program parameters. Press Jog/Purge but-  
ton to clear error.  
MOTR COM  
The motor communication error indi-  
cates motor board lost data communica-  
tions. Press Jog/Purge button to clear error.  
REL TRIG  
E STOP  
PLS WAIT  
The release trigger error indicates the  
user held the trigger when starting a weld  
program Press Jog/Purge button to clear  
error.  
The uim communication error indicates  
The emergency stop error occurs if the  
user presses an emergency stop button.  
Reset the emergency stop button and press  
Jog/Purge button to clear error.  
user  
interface  
board  
lost  
data  
communications. Press Jog/Purge button  
to clear error.  
OVER CRNT  
ERR UNKN  
RMD DONE  
The over current error indicates welding  
power source primary current is too high.  
Check and correct input power. Press Jog/  
Purge button to clear error.  
The RMD done error indicates the RMD The unknown error indicates a malfunc-  
demo is completed. Press Jog/Purge button  
to clear error.  
tion in the system somewhere. Press Jog/  
Purge button to clear error.  
OM-222 394 Page 28  
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8-3. Troubleshooting  
Y
Disconnect power before troubleshooting  
Remedy  
Trouble  
Wire feeds, shielding gas flows, but  
electrode wire is not energized.  
Check gun trigger connection. See gun Owner’s Manual.  
Check gun trigger. See gun Owner’s Manual.  
Electrode wire feeding stops or feeds  
erratically during welding.  
Clean or replace dirty or worn drive roll.  
Incorrect size or worn wire guides.  
Replace contact tip or liner. See gun Owner’s Manual.  
Remove weld spatter or foreign matter from around nozzle opening.  
Have Factory Authorized Service Agency check drive motor or motor control board PC1.  
Check for correct input voltage.  
Motor runs slowly.  
Wire feeder power is on, displays light  
up, but unit is inoperative.  
Check welding gun trigger leads for continuity, and repair leads or replace gun.  
OM-222 394 Page 29  
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SECTION 9 ELECTRICAL DIAGRAM  
Figure 9-1. Circuit Diagram  
OM-222 394 Page 30  
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218 564-D  
OM-222 394 Page 31  
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SECTION 10 PARTS LIST  
. Hardware is common and  
not available unless listed.  
6
7
5
8
9
10  
11  
12  
11  
10  
9
13  
14  
16  
17  
18  
3
15  
19  
2
1
20  
22  
804 023-A  
Figure 10-1. Main Assembly  
OM-222 394 Page 32  
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Item  
No.  
Part  
No.  
Description  
Quantity  
. . . 1 . . . . . . . . . . . . . . . 159 647 . . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 2 . . . . . . . . . . . . . . . 159 646 . . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 3 . . . . . . . . . . . . . . . 159 360 . . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
. . . 4 . . . . . . . . . . . . Figure 10-3 . . DRIVE ASSEMBLY, wire S/L 4 roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . . . . . . . . . . 143 160 . . HUB & SPINDLE ASSEMBLY, (including) . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . . . . . . 180 573 . . . . SHAFT ASSY, support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . SPRING, cprsn .970 OD x .120 wire x 1.250pld . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . WASHER, flat .632 ID x 1.500 OD x .125thk stl pld .175 keyed . . . . . 2  
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . WASHER, flat .656 ID x 1.500 OD x .125thk fbr . . . . . . . . . . . . . . . . . . 2  
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . . . . . . 071 730 . . . . TUBING, stl .875 OD x 12 ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . . . . . . 135 205 . . . . NUT, .625-11 .94 hex .77H stl pld elastic stop nut . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . . . . 141 411 . . SUPPORT, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . . . 208 339 . . KNOB, w/extension (LH) clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . . . . . . 208 338 . . KNOB. w/extension (RH) clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . 156 243 . . CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 18 . . . . . . . . . . . . . . . 145 639 . . STRIP, buna N compressed sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . 2  
. . . 19 . . . . . . . . . . . . . . . 139 226 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . . . 134 306 . . FOOT, rubber 1.250 dia x 1.375 high no 10 screw . . . . . . . . . . . . . . . . . . 4  
. . . 21 . . . . . . . . . . . . Figure 10-2 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . . . . . . . . . . 220 350 . . DRIVE ASSY, wire RT 4 roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-222 394 Page 33  
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. Hardware is common and  
not available unless listed.  
10  
2
1
9
12  
14  
13  
15  
16  
17  
11  
18  
19  
6
3
8
5
4
7
29  
20  
28  
21  
11  
22  
23  
27  
24  
25  
26  
804 024-C  
Figure 10-2. Control Box  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
. . . 1 . . . . . . . . . . . . . . +220 321 . . WRAPPER, feeder dual Axcess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . . . . . . 134 464 . . LABEL, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . . . . . . 211 164 . . PANEL, pc card switch/overlay (including) . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . . . . . . . . . . . . . 210 655 . . . . NAMEPLATE, overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . PC5 . . . . . 227 879 . . . . CIRCUIT CARD ASSY, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . PC7 . . . . . 204 049 . . . . USER INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . PC6 . . . . . 209 681 . . WIRE FEED MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . . . . . . 134 201 . . STANDOFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
. . . 9 . . . . PC2 . . . . . 212 493 . . CIRCUIT CARD ASSY, motor filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 10 . . . . . . . . . . . . . . . 220 063 . . CIRCUIT CARD ASSY, relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . . . . . . . . . . . 010 494 . . BUSHING, snapin nyl 1.375 id x 1.750 mtg hole . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . . 220 314 . . FILTER ASSY, sense lead (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . . . 038 855 . . . . BLOCK, term 20 amp 2 pole screw term . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 13 . . . . . . . . . . . . . . . 216 696 . . . . CAPACITOR, w/terminals (.027UF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 14 . . . . . . . . . . . . . . . 224 383 . . . . RESISTOR, w/terminals (2K 5 watt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . . . 220 458 . . . . CABLE, volt sense 23 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . S1 . . . . . . 213 632 . . SWITCH, rocker dpdt 10A 250VAC/20A 30VAC on-none-on . . . . . . . . . 1  
. . . 16 . . . . RC1 . . . . . 211 018 . . CONNECTOR, circ 97/met 9 pin size 20 rcpt . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . 221 989 . . FITTING, w/screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . 137 761 . . NUT, 750 npt 1.31 hex .27h nyl blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
+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-222 394 Page 34  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
. . . 19 . . . . . . . . . . . . . . . 030 170 . . BUSHING, snapin nyl .750 ID x 1.000 mtg hole . . . . . . . . . . . . . . . . . . . 2  
. . . 20 . . . . . . . . . . . . . . . 219 047 . . VALVE, 40 VDC 2 way custom port 1/8 orf w/frict . . . . . . . . . . . . . . . . . . . 2  
. . . 21 . . . . . . . . . . . . . . . 125 473 . . HOSE, SAE .187 ID X .410 OD X 27.000 . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . . . . . . . . . . 097 132 . . STANDOFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
. . . 23 . . . . . . . . . . . . . . . 220 320 . . ENCLOSURE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . . . 206 765 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . . . 221 081 . . NAMEPLATE, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . S2 . . . . . . 200 295 . . SWITCH, rocker spdt 15A 12V (on)-off-(on) . . . . . . . . . . . . . . . . . . . . . . . 2 . .  
. . . 27 . . . . . . . . . . . . . . . 201 641 . . SWITCH, rocker spdt 15A 12V (on)-off-(on) . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 28 . . . . . . . . . . . . . . . 179 851 . . KNOB, pointer 1.670 dia x .250 id push on w/spring . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . PC1 . . . . . 212 459 . . CIRCUIT CARD ASSY, trigger filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
+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-222 394 Page 35  
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11  
. Hardware is common and  
18  
not available unless listed.  
12  
13  
14  
15  
Drive Roll & Wire Guide Kits  
16  
17  
9
7
8
6
5
4
3
18  
2
1
19  
10  
15  
20  
33  
21  
22  
23  
24  
32  
31  
30  
25  
35  
26  
6
5
29  
34  
27  
28  
4
3
2
1
802 950-B  
Figure 10-3. Drive Assembly, Wire  
Item  
No.  
Dia.  
Mkgs.  
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 . . . . . . 213 005 . . MOTOR, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 203 631 . . PRESSURE ARM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . . . . . . 182 415 . . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . . . . . . . . . . . 203 640 . . . . KNOB, w/extension short pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 12 . . . . . . . . . . . . . . . 203 641 . . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 13 . . . . . . . . . . . . . . . 182 156 . . . . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 14 . . . . . . . . . . . . . . . 182 155 . . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 15 . . . . . . . . . . . . . . . 132 746 . . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 16 . . . . . . . . . . . . . . . 203 633 . . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . . . . . . . . . . . . 203 632 . . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . . . 133 739 . . . . WASHER, flat buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . 2  
. . . 19 . . . . . . . . . . . . . . . 203 637 . . . . KNOB, w/extension long pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . . . 229 550 . . ENCODER, quadrature 500PPR incremental 5V shaftless . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 604 311 . . . . GROMMET, rbr .250 ID x .375mtg hole .062 groove . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 603 115 . . WEATHER STRIPPING, adh .125 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . . . 167 387 . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
OM-222 394 Page 36  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
. . . 22 . . . . . . . . . . . . . . . 168 825 . . DRIVE, pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . . . 133 308 . . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 24 . . . . . . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 2ft  
. . . . . . . . . . . . . . . . . . . . . 184 685 . . ADAPTER ASSY, gun/feeder LH (including) . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 25 . . . . . . . . . . . . . . . 149 959 . . . . FITTING, brs barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 26 . . . . . . . . . . . . . . . 179 265 . . . . ADAPTER, gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 27 . . . . . . . . . . . . . . . 604 538 . . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 28 . . . . . . . . . . . . . . . 151 437 . . . . KNOB, plstc T 1.125 lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 29 . . . . . . . . . . . . . . . 185 624 . . . . SCREW, 010-32 x o.50 hexwhd .40D stl pld slffmg trilob . . . . . . . . . . . . 2  
. . . 30 . . . . . . . . . . . . . . . 601 872 . . . . NUT, stl hex full fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 31 . . . . . . . . . . . . . . . 602 213 . . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 32 . . . . . . . . . . . . . . . 602 243 . . . . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 33 . . . . . . . . . . . . . . . 601 966 . . . . SCREW, cap stl hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 34 . . . . . . . . . . . . . . . 108 940 . . SCREW, cap stl hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 35 . . . . . . . . . . . . . . . 179 263 . . COVER, drive roll (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . . 178 937 . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.  
Table 10-1. Drive Roll And Wire Guide Kits  
Wire Size  
V-GROOVE  
4 Roll Drive  
Kit Roll  
U-GROOVE  
4 Roll Drive  
Kit Roll  
VK-GROOVE  
UC-GROOVE  
Inter-  
mediate  
Guide  
Inlet  
Guide  
4 Roll  
Kit  
Drive  
Roll  
4 Roll  
Kit  
Drive  
Roll  
Fraction  
Metric  
.023-.025in.  
.030 in.  
0.6 mm  
0.8 mm  
0.9 mm  
1.0 mm  
150 993  
150 993  
150 993  
150 993  
149 518  
149 518  
149 518  
149 518  
149 519  
149 519  
151 024 087 130  
151 025 053 695  
151 026 053 700  
161 189 053 696  
151 027 053 697  
151 028 053 698  
.035 in.  
151 036  
072 000  
151 052  
132 958  
.040 in.  
.045 in.  
1.1/1.2 mm 150 994  
1.3/1.4 mm 150 994  
151 037  
151 038  
053 701  
053 702  
151 053  
151 054  
132 957 151 070 083 489  
132 956 151 071 083 490  
.052 in.  
1/16 in.  
1.6 mm  
1.8 mm  
2.0 mm  
150 995  
150 995  
150 995  
149 520  
149 520  
149 520  
151 029 053 699  
151 039  
053 706  
151 055  
151 056  
151 057  
132 955 151 072 053 708  
132 959  
(.062 in.)  
.068-.072 in.  
5/64 in.  
(.079 in.)  
151 040  
151 041  
151 042  
151 043  
053 704  
053 703  
053 705  
053 707  
132 960 151 073 053 710  
3/32 in.  
(.094 in.)  
2.4 mm  
2.8 mm  
3.2 mm  
150 996  
150 996  
159 997  
149 521  
149 521  
149 522  
151 058  
151 059  
151 060  
132 961 151 074 053 709  
132 962 151 075 053 711  
132 963 151 076 053 712  
7/64 in.  
(.110 in.)  
1/8 in.  
(.125 in.)  
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls.  
OM-222 394 Page 37  
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Notes  
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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 200601  
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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 HeadquartersUSA  
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  
www.MillerWelds.com  
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.200601  
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