OM-1500-7
204 129H
2007−07
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
D-74DX
File: MIG (GMAW)
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-3. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Equipment Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-6. Wire Type, Size, And Feed Speed Capability Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-7. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-8. Setting Internal DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-9. Power Source Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-3. Left/Right Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-4. Jog/Purge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-5. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-6. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-7. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-8. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-9. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-10. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-11. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-12. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-1. Optional Dual Schedule Switch Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-3. Diagnostics For User Defined Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
D-74DX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 5: Wire Feeders. IEC 60974-5 Ed. 1
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems −
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_wire_6/05
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
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Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
. Indicates special instructions.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
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Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
follow all Safety Standards.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and
repair this unit.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
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Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
ELECTRIC SHOCK can kill.
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Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
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Do not connect more than one electrode or work cable to any
single weld output terminal.
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SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
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Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
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Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
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To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
OM-1500-7 Page 1
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Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
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If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
FLYING METAL or DIRT can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
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Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
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Wear approved safety glasses with side
shields even under your welding helmet.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
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Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
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ImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
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Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
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Wear approved ear protection if noise level is
high.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
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Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
OM-1500-7 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
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Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING UNIT can cause injury.
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Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
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Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
D
Do not block or filter airflow to unit.
D
FLYING SPARKS can cause injury.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D
D
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
If notified by the FCC about interference, stop using the
equipmentat once.
D
D
Have the installation regularly checked and maintained.
D
Sparks can cause fires — keep flammables away.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
D
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
D
OM-1500-7 Page 3
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1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044,website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900,website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 5060 Mississauga,
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1500-7 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2007−04
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
. Indique des instructions spécifiques.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re-
commandée.En outre, ne pas travailler seul !
Les symboles représentés ci-dessous sont utilisés dans ce ma-
nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec-
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentationselon la norme OSHA 29 CFR 1910.147 (voir nor-
mes de sécurité).
Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
nationales,provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D
D
Seul un personnel qualifié est autorisé à installer, faire fonc-
tionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes,notamment les enfants de l’appareil.
D
D
En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
D
D
Ne pas toucher aux pièces électriques sous tension.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
D
D
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D
D
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide dou-
blée.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil
conformémentà ce manuel.
D
D
Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D
D
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
D
D’autres consignes de sécurité sont nécessaires dans les condi-
tions suivantes : risques électriques dans un environnement
humideou si l’on porte des vêtements mouillés ; sur des structures
métalliquestelles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
D
Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
D
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-1500-7 Page 5
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Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a
coupé l’alimentation.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
D
Arrêter les convertisseurs, débrancher le courant électrique et
déchargerles condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliquespeut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D
Ne pas toucher à mains nues les parties
chaudes.
D
Prévoir une période de refroidissement avant de
travailler à l’équipement.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusementavec des protections homologués.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
D
D
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereux pour votre santé.
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
mes de sécurité).
D
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais-
seurs.
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
quant des risques d’électrocution, d’étincelles et d’incendie.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtementset tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
D
D
D
D
D
D
Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D
Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliquesvolantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
D
Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
D
OM-1500-7 Page 6
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D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D
Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D
Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
d’air homologué.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
D
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de sou-
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécu-
rité.
dage, les manipuler avec précaution.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Porter un écran facial pour protéger le visage et
les yeux.
D
Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D
Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv-
re est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
LA CHUTE DE L’APPAREIL peut
blesser.
D
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Prévoir une période de refroidissement ; re-
specter le cycle opératoire nominal.
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D
D
Ne pas obstruer les passages d’air du poste.
OM-1500-7 Page 7
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LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Maintenirfermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec-
tion.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D
L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et l’é-
quipement commandé par ordinateur tel que
les robots.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
D
Veiller à ce que tout l’équipement de la zone de soudage soit
compatibleélectromagnétiquement.
D
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentairestelles que le déplacement du poste, l’utilisation de câ-
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
D
D
D
N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
D
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
2-4. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmesde procréation. Se laver les mains après manipu-
lation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
OM-1500-7 Page 8
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2-5. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900,site Internet : www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone
1-877-413-5184,site Internet : www.global.ihs.com).
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-
tilly, VA 20151 (téléphone
www.cganet.com).
:
703-788-2700, site Internet
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
CanadianStandards Association, 5060 Mississauga, Ontario, Canada
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa-
miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiqueset champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-1500-7 Page 9
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OM-1500-7 Page 10
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SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
A
B
C
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1
Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1
2
1.1
2.1
3.1
4.1
1.2
1.3
1.3 Disconnect input plug or
power before working on
machine.
2
Breathing welding fumes can
be hazardous to your health.
2.2
2.3
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3
4
5
3.2
3.3
3
Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
+ + +
3.3 Do not weld on drums or any
closed containers.
4
Arc rays can burn eyes and
injure skin.
6
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
+
S-178 936
5
Become trained and read the
instructions before working on
the machine or welding.
6
Do not remove or paint over
(cover) the label.
OM-1500-7 Page 11
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3-2. Rating Label For CE Products
. For label location
S/N:
U1
I =
1
50/60 Hz
IP 21
24 V
10.0A
1
=
U2
=
I =
750 A
2
100 V
X 100 %
ST-178 794-A
3-3. WEEE Label (For Products Sold Within The EU)
Do not discard product (where ap-
plicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
3-4. Symbols And Definitions
. Some symbols are found only on CE products.
Amperes
Volts
Alternating Current
Program
Duty Cycle
A
IP
V
Hz
X
Degree Of
Protection
Hertz
Wire Feed
Jog
Output
Trigger
Line Connection
Set Up
Sequence
Trigger Hold On
Trigger Hold Off
Crater
Purge
Time
Press To Set
Preflow Time
Start
Postflow Time
Rated Current
Read Instructions
Increase
Primary Current
Dual Schedule
Load Voltage
I1
I2
U2
A
B
Primary Voltage
U1
OM-1500-7 Page 12
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SECTION 4 − INTRODUCTION
4-1. Specifications
Welding
Circuit
Rating
Type of Input
Power
Welding Power
Source Type
Wire Feed Speed
Range
Wire Diameter
Range
IP
Rating
Overall
Dimensions
Weight
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Constant Voltage (CV)
DC With 14-Pin And
Contactor Control
Standard: 50 To 780
.023 To 1/8 in
100 Volts,
750
Amperes,
100% Duty
Cycle
IP 21
Length: 35 in
(889 mm)
87 lb
(39.5 kg)
ipm (1.3 To 19.8 mpm) (0.6 To 3.2 mm)
Width: 12-1/2 in
(318 mm)
Optional High Speed:
92 To 1435 ipm (2.3
To 36.4 mpm)
Max Spool
Weight: 60 lb
(27 kg)
Height: 14 in
(356 mm)
Optional Low Speed:
19 to 300 ipm
(0.4 to 7.6 mpm)
SECTION 5 − INSTALLATION
5-1. Site Selection
!
Do not put feeder where
welding wire hits cylinder.
3
Do not move or operate
equipmentwhen it could tip.
4
1
2
Wire Feeder
Rubber Feet
1
Choose slot that allows all rubber
feet to sit securely on top of welding
power source.
5
3
4
Wire Spool/Reels
Gas Cylinder w/Hose And
Regulator (Customer
Supplied)
2
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
5
6
Welding Power Source
Running Gear
. Factory voltage settings are V-
Min 10 and V-Max 38. If you are
using a power source with a dif-
ferent voltage range, see Sec-
adjustments.
6
Wire feeder shown is representative
only and does not reflect actual unit.
Ref. 803 053
OM-1500-7 Page 13
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5-2. Equipment Connection Diagrams
1
2
3
4
5
6
7
8
9
Welding Power Source
Contactor Control/Power Cord
Positive (+) Weld Cable
Negative (−) Weld Cable
Workpiece
Welding Gun
Wire Feeder
Gas Hose
Gas Cylinder and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
1
9
2
3
4
5
8
7
6
803 073
OM-1500-7 Page 14
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5-3. Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable - 10 Ft
(3.0 m)
Shielding Gas Valve Fittings
Requires fitting with 5/8-18 right-
hand threads. Connect customer-
supplied gas hose.
3
4
5
6
7
Weld Cable Terminal
Jumper Weld Cable
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
8
Rating Label Location
To rotate the drive assembly, loos-
en drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
8
2
1
5
4
3
4
5
6
7
Tools Needed:
9/16, 5/8 in
3/16 in
803 067 / 802 825-A
OM-1500-7 Page 15
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5-4. 14-Pin Plug Information
Pin*
Pin Information
A
B
G
C
D
E
H
F
24 volts ac with respect to socket G.
Contact closure to A completes 24 volts ac contactor control circuit.
Circuit common for 24 volts ac circuit.
J
A
K
I
B
C
L
H
N
+10 volts dc input from power source to wire feeder with respect to socket D.
Remote control circuit common.
M
E
G
D
F
0 to +10 volts dc output signal from wire feeder to power source with respect to socket D.
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
*The remaining pins are not used.
5-5. Gun Recommendation Table
Process
Gun
GMAW − Hard or Cored Wires
Roughneck C-Series Guns: 300,
400, 500, And 600 Amp.
FCAW − Self-Shielding Wires
FC-1260 Or FC-1150
5-6. Wire Type, Size, And Feed Speed Capability Table
Motor Speed
Standard
Wire Type
Wire Size
Feed Speed Capability
All
All
All
.023 To 5/64 in (0.6 To 2 mm)
3/32 To 7/64 in (2.4 To 2.8 mm)
1/8 in (3.2 mm)
50 To 780 ipm (1.2 To 19.8 mpm)
50 To 700 ipm (1.2 To 17.8 mpm)
50 To 300 ipm (1.2 To 7.6 mpm)
Standard
Standard
Optional High
Speed
All
All
.023 To 5/64 in (0.6 To 2 mm)
.023 To 1/8 in (0.6 To 3.2 mm)
92 To 1435 ipm (2.3 To 36.4 mpm)
19 To 300 ipm (0.4 To 7.6 mpm)
Optional Low
Speed
OM-1500-7 Page 16
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5-7. 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
Pressure
Adjust
Rear
Scale
Pressure
Adjust
Front
Rolls
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Tools Needed:
Drive Rolls
3/16, 5/64 in
15/16, 3/8 in
Back Of Gun
End Of Liner
. For best wire feeding performance, be . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
sure that the outlet cable has the proper
size liner for the welding wire size being
used. Also, when the gun is installed, the
liner extending from the back of the gun
should be as close to the drive rolls as
possible, without touching.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If con-
tact tip is completely blocked, wire should
slip at the feeder (see pressure adjust-
ment above).Cut wire off. Close cover.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A
OM-1500-7 Page 17
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5-8. Setting Internal DIP Switches
1
2
DIP Switch S1
DIP Switch S4 (Not For Customer Use)
DIP switch S1 allows the user to make a num-
ber of choices affecting unit operation.
w Defining Motor Speed (S1-7 & 8)
Switches 7 and 8 allow the user to define
whether the motor in use is standard speed
(50-780 inches per minute), or high speed
(92-1435 inches per minute), or low speed
(19-300 inches per minute).
. When DIP switch positions are changed, the
unit must be turned Off and then On again in
order for the new settings to be active. DIP
switches are only read on power up.
1
O
N
1
2
3
4
5
6
7
8
. In the DIP switch S1 illustrations,
the elevated slider on each switch
is shown in white. For example,
the switches above are all in the
Off position.
2
802 808
Position Settings And Results For DIP Switch S1
7
7
8
8
7
8
7 Off, 8 Off = Standard
speed motor (50-780 inch-
es per minute, or 1.2-19.8
meters per minute)
7 On, 8 On = Low Speed
Motor (19-300 inches per
minute, or 0.4-7.6 meters per
minute).
7 Off, 8 On = High speed
motor (92-1435 inches per
minute, or 2.3-36.4 meters
per minute)
OM-1500-7 Page 18
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5-9. Power Source Selection Menu
1
2
Upper Display
Lower Display
Non-CE Model Shown
1
. When the feeder is turned on,
the Power Source Selection
Menu allows the operator to se-
lect a default power source.
Selecting
a
default power
source, automatically sets the
correct Vmin and Vmax set-
tings for adjusting the output
voltage of the power source.
Program
Volts
Time (sec)
First Time Feeder Is Turned On
The feeder automatically goes into
the Power Source Selection Menu.
The feeder displays “dELT” on the
Upper Display and “452” on the
Lower Display, meaning that a Del-
taweld 452 is the default power
source, and has a voltage range of
10V as Vmin and 38V as Vmax.
Wire Speed
Amps
2
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
At power up, the operator has three
seconds to select a default power
source from the list shown on the
display. Operator may scroll
throughthe list of power sources by
using the Adjust control. After se-
lecting a power source the operator
has three seconds to change to a
different power source or begin
welding. After making a power
source selection, the operator may
press the Program Button to avoid
having to wait the three seconds.
When turning off the feeder, the de-
fault power source will be retained.
Sequence
Adjust
Setup
Upper Display
Voltage Range
* * Power Source
Lower Display
Deltaweld 452
Deltaweld 302
Deltaweld 652
Dimension 302
Dimension 452
Dimension 652
Dimension 1000
XMT 304
dELT
dELT
dELT
dIM
452
302
652
302
452
652
1000
304
456
MP
Vmin =10
Vmax =38
Vmax =32
Vmax =44
Vmax =32
Vmax =38
Vmax =65
Vmax =60
Vmax =35
Vmax =38
Vmax =35
Vmax =38
Vmax =38
Vmax =38
Vmax =44
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =25
If voltage settings have already
been set with the Vmin and Vmax in
the Auxiliary Menu, selecting a de-
fault power source with the Power
Source Selection Menu overrides
the Vmin and Vmax voltage set-
tings.
dIM
dIM
dIM
XMT
XMT
I354
I456
I456
PHX
SUM
XMT 456
Next Time Feeder Is Turned On
Invision 354MP
Invision 456MP
Invision 456P
PHOENIX 456
SUMMITARC 1000
The feeder will display the last se-
lected default power source. The
operator has three seconds to se-
lect another power source, or press
the Program Button to exit the Pow-
er Source Selection Menu.
MP
P
456
1000
Disabling The Power Source
Selection Menu
Once the default power source has
been selected the Power Source
Selection Menu may be disabled
using the Auxiliary Menus. See
** For any power sources not listed, pick a matching voltage range, or see Sec 5-12 to
set Vmin and Vmax.
OM-1500-7 Page 19
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SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this wire feeder:
General Terms:
Cold Wire Jog
Sequence
Feeding wire without contactor or gas valve being energized.
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
A group of sequences that make up a weld cycle.
Weld Program
6-2. Power Switch
1
Power Switch
1
Ref. 803 072
6-3. Left/Right Select Switch
1
Left/Right Select Switch
Pressing the Left/Right Select
switch allows the operator to
choose which side of the units’ con-
trols will operate.
. Depressing the Left or Right
Gun Trigger also allows the
operator to enable the con-
trols on that side of the unit.
1
Ref. 803 053
OM-1500-7 Page 20
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6-4. Jog/Purge Switch
1
2
3
Jog/Purge Switch
Adjust Control
Gun Trigger Receptacle
2
3
1
Ref. 803 053
Pressing the Jog/Purge switch allows the op-
erator to jog wire without energizing the weld
power or gas valve circuit.
trigger is still activated after two minutes, the
jog operation is terminated to prevent com-
plete despooling of the wire, in the case of
a damaged gun.
unit displays jog speed when the unit is be-
ing jogged.
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog opera- • Jog speed can be adjusted by the Adjust
tion for a maximum of two minutes. If the gun control when the unit is jogging wire. The
• The unit displays the “ERR TRIG“ message
to inform the operator that the trigger is acti-
vated.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before weld-
ing and to preset gas pressure at the
regulator.
OM-1500-7 Page 21
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6-5. Front Panel Controls
Nameplate For Non-CE Models
See
Section
See
Section
Program
See
Section
Volts
Time (sec)
Wire Speed
Amps
Start
Dual Schedule
Trigger Hold
Crater
Pre/Postflow
Sequence
Adjust
Setup
See
Section
See
Section
See
Section
Nameplate For CE Models
See
Section
See
Section
See
Section
See
Section
See
Section
See
Section
OM-1500-7 Page 22
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6-6. Program Push Button
1
Program Display
Non-CE Models
CE Models
The number of the active program
is displayed.
2
Program Push Button
Press button to activate program
select feature. To change the pro-
gram number, press the Program
push button and rotate the Adjust
control.
1
1
2
3
Program Push Button LED
Program
3
The LED lights to indicate the Pro-
gram push button is active.
3
2
6-7. Upper Display
. To set the correct voltage range for a particular power
Non-CE Models
3
2
1
4
Volts
Time (sec)
5
CE Models
3
2
1
4
5
1
Upper Display
nates to indicate that information displayed
can be changed by the Adjust control.
play push button repeatedly until welding
time is the active parameter in the upper
display. At idle, the upper display toggles
between showing weld voltage or weld
time, with subsequent presses of the up-
per display push button.
The upper display shows voltage or time.
The unit displays both preset and actual arc
voltage. When the unit is in a welding state,
actual arc voltage is displayed. The upper
display shows welding sequence time when
the Time LED is illuminated.
4
5
Volts LED
Time LED
The LEDs below the display illuminate to in-
dicate which value is being shown.
• The unit defaults to displaying welding
voltage when a welding sequence display
mode is first entered.
At any time while welding, the unit permits
the adjustment of the weld sequence voltage
and overrides the display of actual arc volt-
age.
2
Upper Display Push Button
Press and hold button to adjust or display
weld time. Release button to display voltage.
• If the weld sequence has a time set (as in
spot time), after the weld program is com-
pleted, ERR TRG 1 will be displayed to in-
dicate the weld program is complete. Re-
lease trigger to clear error.
• If the unit is displaying a welding sequence
that can be timed, the welding time display
mode is entered by pressing the upper dis-
3
Upper Display Push Button LED
The upper display push button LED illumi-
OM-1500-7 Page 23
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6-8. Lower Display
3
2
1
Non-CE Models
4
Wire Speed
Amps
5
3
1
4
2
CE Models
5
1
Lower Display
to indicate that information displayed can be
changed by the Adjust control.
just control is activated while welding, the
unit displays and permits adjustment of the
weld sequence wire feed speed regardless
of the active welding sequence.
The lower display shows wire speed or
amperage.The unit displays and adjusts only
preset wire speed at idle. When the unit is in a
welding state, actual wire speed is displayed
for the active welding sequence.
4
5
Wire Speed LED
Amps LED
• When the unit is displaying amperage, the
Amps LED illuminates. Amperage is only
displayed if the unit is in a welding state and
the amperage is above a minimum value of
25 Amps.
The LEDs below the display illuminate to indi-
cate which value is being shown.
2
Lower Display Push Button
• If the unit is in a welding state that does not
involve feeding wire, the unit displays the
weld sequence wire speed. At any time dur-
ing welding, the weld sequence wire speed • The display will read dashes for amperage
can be adjusted and overrides the preset
wire speed display. In other words, if the Ad-
Press button to choose between wire speed or
amperagefunctions.
3
Lower Display Push Button LED
readings below the amperage threshold,
prior to arc initiation.
The lower display push button LED illuminates
6-9. Setup Push Button
3
3
4
Trigger Hold
4
2
Dual Schedule
2
1
1
Setup
Non-CE Models
CE Models
1
Setup Push Button
the trigger hold status or press the lower dis- • When the Setup button is pressed a second
play push button. If trigger hold is turned On,
the trigger hold LED illuminates and stays
On.
time, the dual schedule LED flashes. In this
mode the upper display indicates DUAL and
the lower display indicates dual schedule
status On/Off. Use the Adjust control to
change the dual schedule status if desired.
Press button to choose between trigger hold
or dual schedule functions.
2
3
4
• When the Setup button is pressed, the Set-
up push button LED flashes and the Trigger
Hold LED flashes.
Setup Push Button LED
Trigger Hold LED
Dual Schedule LED
• When trigger hold is On, the user must
press and hold the trigger for a predefined
amountof time (the trigger hold delay time−
ger hold function to be active. To shut off the
weld when trigger hold is On, the user must
press and release the trigger.
• Pressing the Setup button again exits the
Setup mode. The dual schedule LED stops
flashingto indicate the dual schedule status
is Off.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
the upper display indicates HOLD and the
• While in the Setup mode, the active program
can be adjusted without deactivating the
trigger hold Setup mode operation. If the
trigger is activated, Setup mode(s) is termi-
nated.
• If a weld time is programmed, trigger hold is
disabled.
lower display indicates the trigger hold sta- • Trigger hold and dual schedule cannot be
tus On/Off. Use the Adjust control to change
used concurrently.
OM-1500-7 Page 24
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6-10. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parame-
ters, and to select various se-
quences. Refer to the section for
the function in question for informa-
tion related to using the Adjust con-
trol.
1
1
Adjust
Non-CE Models
CE Models
6-11. Sequence Push Button
1
2
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
Start
3
3
Crater
Pre/Postflow
Weld
2
1
Start
Time
Crater
Time
2
Time
Preflow
Time
1
Postflow
Time
Sequence
Welding Sequence Diagram
Non-CE Models
CE Models
the weld display mode is activated.
• When the Sequence push button is pressed
a third time, the Preflow/Postflow sequence
LED flashes. The Sequence push button
LED remains flashing. In the Preflow display
mode the upper display shows the preflow
time and the lower display indicates the ab-
breviation PRE, to inform the operator that
preflow time is displayed. If the upper dis-
play push button is pressed, the Adjust con-
trol can be used to adjust preflow.
. For more information on Setting
If zero time is programmed for a timed se-
quence except for Weld, that sequence will
be skipped.
• The Sequence push button allows the
selection of welding sequences. Five weld-
ing sequences are available. The default
sequence is the Weld sequence. The Weld
sequence is active on power up. Three
welding sequence LEDs are located above
the Sequence push button: Start, Crater,
and Preflow/Postflow. The applicable LED
illuminates to indicate which welding se-
quence is active.
• In the weld sequence display mode the Se-
quence push button LED is Off. When the
Sequence push button is pressed, the Se-
quence push button flashes and the Start
LEDs flash. In this condition, the unit is in the
Start sequence display mode, and Start se-
quence parameters are shown in the dis-
plays.
If the lower display push button is pressed, the
Adjust control can be used to select between
preflow PRE and postflow POST. When
POST is selected, the upper display can be
used to specify postflow time.
• When the Sequence push button is pressed
a second time, the Crater sequence LED
flashes. The Sequence push button LED re-
mains flashing. In this condition, the unit is
in the Crater sequence display mode, and • When the Sequence push button is pressed
Crater sequence parameters are shown in
the displays.
• The LED illuminates to indicate that a weld-
ing sequence display mode other than Weld
is activate. Welding sequences other than
Weld must be set prior to initiating the arc.
When the unit enters a welding state, all se-
quence display modes are terminated and
a fourth time, the unit returns to the welding
sequence display mode.
OM-1500-7 Page 25
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6-12. Auxiliary Menus
1
2
3
4
5
6
7
8
9
Program Display
Non-CE Models
Program Push Button
Sequence Push Button
Upper Display
4
5
7
1
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
2
Program
Volts
Time (sec)
Setup Push Button
Wire Speed
Amps
6
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
9
3
Sequence
Adjust
Setup
8
CE Models
4
5
1
2
7
6
9
3
8
OM-1500-7 Page 26
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6-12 Auxiliary Menus (Continued)
Reset To Factory Settings
is used to select either “On” or “Off”.
the trigger hold delay time. For example, if
a trigger hold delay time of 2.0 seconds is
defined,and the operator held the trigger in
for more than 6.0 seconds, the trigger hold
function would not be in effect and the wire
feeder would stop when the trigger is rele-
ased.
Arc Time
A reset menu is displayed if the following four
push buttons are pressed simultaneously:
Program, Sequence, upper display, and Set-
up. The upper display indicates “WIPE” . The
lower display indicates “OFF”. The lower
push button is active indicating that the Adjust
control can be used to change the unit to
“WIPE ON”. When “WIPE ON” is set, if the ori-
ginal four push buttons are simultaneously
pressed a second time, the unit will reset all
settings to factory default except the arc time
and arc cycle counts. If a reset is not desired,
set the display to “WIPE OFF” and simulta-
neously press the Program, Sequence, upper
display, and Setup push buttons to exit the re-
set menu.
• If the Setup push button is pressed, the unit
displays arc time in hours.
Arc time is indicated by the Program display
showing “HR”. Arc time is shown in the lower
display.
• When the Setup push button is pressed
again, the menu repeats to the first menu
selection of run-in wire speed selection.
Cycles
• If the Setup push button is pressed, the unit
displays the number of cycles.
Trigger Program Select
• If the Setup push button is pressed, the unit
allows Trigger Program Select or Trigger
Dual Schedule to be enabled or disabled.
Arc cycles are indicated by the Program dis-
play showing “CL”. The arc cycle count is
shown in the lower display.
The upper display shows “TSEL”. Lower dis-
play shows “OFF” or “PROG” or “DUAL”. The
Adjust Control is used to select “OFF” or
“PROG” or “DUAL”.
Run-In
• If the Setup button is pressed, the unit al-
lows setting the run-in modes. The run-in
modes are program specific. Each program
may be set to its own run-in mode.
Auxiliary Menu
• An auxiliary menu is provided if both the Se-
quence and Setup push buttons are
pressed simultaneously. The Setup push
button and sequence push button LEDS
flash when the auxiliary menu is displayed.
Trigger Program Select (PROG) allows the
operatorto select programs during preflow by
clicking the trigger (pulling and releasing the
trigger in a maximum of 0.2 seconds). The
feeder will switch between any programs that
have a minimum of 0.2 seconds of preflow
time set in the weld sequence. Any combina-
tion of programs may be used. Trigger Pro-
gram Select cannot be used while welding or
with Dual Schedule.
(Example: If programs 1 and 3 have a mini-
mum of 0.2 seconds of preflow time, clicking
the trigger will toggle between programs 1
and 3).
The upper display indicates “RUNI”. The
lower display indicates “AUTO”, meaning
the factory set automatic run-in speed is
selected.
Pushing the Setup push button will step
through the menu. Pushing the sequence
push button will step through the menu in re-
verse.
Pressing the lower display button allows a
manual setting the run-in wire speed. Speed
may be adjusted from 10% to 100% of weld
wire speed.
. The auxiliary menu may be exited at any
time by pressing both the Sequence push
button and the Setup push buttons simul-
taneously.
Pressing the lower display button allows
disabling of the run-in feature. When the
lower display indicates “OFF” run-in is dis-
abled.
V-Min And V-Max
Trigger Dual Schedule Select (DUAL) allows
the operator to switch between paired sched-
ules (programs 1−2, 3−4, 5−6, or 7−8) with the
gun trigger, but only while welding. This fea-
ture cannot be used with Trigger Hold or Dual
Schedule. To end the weld, the trigger must
be released for 0.4 seconds.
(Example: when welding with this feature en-
abled in program 1, if you release, re-trigger,
and hold again within <0.4 seconds, the ac-
tive program will switch to program 2. If the
previous sequence is repeated the active pro-
gram will switch back to program 1. This cycle
can be repeated for the entire weld).
Burnback
• If the Setup push button is pressed, the unit
allows the setting of the manual override
power source min and max voltage preset
range. The minimum voltage is displayed in
the upper display and the lower display indi-
cates “VMIN”. When the Setup push button
is pressed the unit displays the maximum
voltage setting of the welding power
source. The maximum voltage is displayed
in the upper display and the lower display
indicates “VMAX”.
• If the Setup push button is pressed, the unit
allows burnback time to be set.
Burnback time and voltage can be specified
when the lower display indicates “BURN” and
the upper display indicates the burnback time
or voltage. The Adjust control is used to set
the desired burnback time or voltage. Burn-
back settings, like run-in settings, are pro-
gram specific. The active program is dis-
played in the Program display and can be ad-
In both cases, the Adjust control is used to
specify the minimum and maximum voltage
settings of the welding power source. The
settings correspond to arc voltage obtained at
minimumcommand and arc voltage obtained
at maximum command.
Trigger Hold Setup
Process Select
• If the Setup push button is pressed, the unit
allows trigger hold delay time to be set.
Process selection indicated by ”PROS” in the
upper display is set to either ”VOLT” or
”TRIM” in the lower display. Each program
can be selected be be a MIG program indi-
cated by ”VOLT” or a pulsing program indi-
cated by ”TRIM”.
Trigger hold delay time is indicated by
”HOLD” in the lower display and the hold
delay time in the upper display. The adjust
control can be used to specify a new delay
time for trigger hold. Trigger hold delay time is
the minimum amount of time the trigger must
be held for trigger hold to work when the trig-
ger is released (the trigger hold function must
be on). For example, if a trigger hold delay
time of 2.0 seconds is defined, the operator
must hold the trigger for at least 2 seconds be-
fore releasing it in order for the trigger hold
function to work. Once the trigger hold func-
This method of setting “VMIN” and “VMAX”
may be used if the power source being used
is not listed in the Power Source Selection
Menu.
Range Locks
. If a default power source has already
been selected with the Power Source
Selection menu, setting “VMIN” and
“VMAX” will override the default power
source settings.
Range locks are indicated by “LOCK” in the
upper display for wire speed or “LOCK” in the
lower display for voltage range. In a MIG pro-
gram, the voltage range lock ranges from 0 to
10 volts. In a pulse program, the trim range
lock ranges from 0 to 100. The wire feed
speed range lock ranges from 0 to 250 ipm.
Locks are program dependent and wire
speed is independent from voltage or trim.
. The power source selection menu must
be set to “OFF” when overriding the de- tion is in effect, the wire feeder will stay On un-
fault “VMIN” or “VMAX” settings.
til the trigger is pressed and released again.
• There is an additional function built in called
”maximum trigger hold time” which is the
maximum length of time the trigger can be Wire feed speed setting indicated by “WFS”
held and the trigger hold function still work in the upper display is set to “IPM” inches−
when the trigger is released (the trigger
hold function must be on). The maximum
trigger hold time is set at 4.0 seconds after lected.
Power Source Selection Menu
Wire Feed Speed Units
• If the Setup push button is pressed, the unit
allows the Power Source Selection menu to
be disabled or enabled.
per−minute or ”MPM” meters−per−minute.
This setting is independent of the program se-
The upper display shows “PSS”. Lower dis-
play shows “On” or “Off”. The Adjust Control
OM-1500-7 Page 27
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6-12 Auxiliary Menus (Continued)
OPT1
quence if shielding gas flow to the gun is inter-
“CODE” in the top display should be activated.
By default the code is off, indicated by “OFF”
in the lower display. The user may enter a nu-
merical password between 0 and 999 by turn-
ing the Adjust control. When the user re−en-
ters the auxiliary menu, the password code
must be selected to gain access to the auxilia-
ry menu. A failed attempt return the user to the
weld screen and a counter is incremented. A
counter in the program display shows the
number of incorrect attempts. The user has
five attempts to enter the correct password
code before being locked out of the auxiliary
menu, indicated by “LOCK” in the lower dis-
play . The power may be cycled to continue
welding but the user will remained locked out
of the auxiliary menu. Pressing the Program,
Sequence, upper display, and Set−up push
buttons simultaneously, the counter can be re-
set in the weld screen. Resetting the counter
is indicated by “CODE” in the upper display
and “RSET” in the lower display. Pressing the
Program, Sequence, upper display, and Set−
up push buttons simultaneously again will al-
low the user to reset the unit to the factory de-
faults, indicated by “WIPE” in the upper dis-
play. Resetting the unit will also turn off the
password code feature.
rupted. A closed set of contacts between pins
1 and 2 of RC24 on Interface Board (PC20)
will allow feeder to operate normally. Opening
the contacts will stop the weld sequence and
display “ERR” in the upper display and
“OPT2” in the lower display.
• If the Setup push button is pressed, the unit
allows OPT1 to be disabled or enabled.
The upper display shows “OPT1”. Lower dis-
play shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
“OPT1” is used by the Water Flow Shutdown
Option to stop the weld sequence if water flow
to a water cooled gun is interrupted. A closed
set of contacts between pins 1 and 2 of RC26
on Interface Board (PC20) will allow feeder to
operate normally. Opening the contacts will
stop the weld sequence and display “ERR” in
the upper display and “OPT1” in the lower dis-
play.
Display Hold
Display hold indicated by ”DISP” in the upper
display is set to “OFF” or “HOLD” in the lower
display. When ”HOLD” is selected, the unit will
hold the last weld information for 5 seconds
following weld termination. If any front panel
push button is pressed, or if the Adjust control
is activated, the display hold feature is termi-
nated.
OPT2
Software Revision Level
• If the Setup push button is pressed, the unit
allows OPT2 to be disabled or enabled.
• If the Setup push button is pressed, the unit
displays the software version being used by
the interface PCB (PC20).
The upper display shows “OPT2”. Lower dis-
play shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
• When the Setup button is pressed again, the
menu repeats.
“OPT2” is a second input that may be used
with an external device, such as a gas flow
switch, to end the weld sequence. The gas
Code
Upon leaving the auxiliary menu, the user is
flow switch may be used to stop the weld se- asked if a password code indicated by
Notes
OM-1500-7 Page 28
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SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence Push Button see
If time is set to zero in Weld
sequence, welding continues until
Sequence
Parameters
gun trigger is released.
Volts
X
IPM
Seconds
0-9.9
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
1. Preflow
2. Run-In
3. Start
X
X
X
X
0.00-5.00
0-100.0
4. Weld
X
X
X
5. Crater
6. Burnback
0-5.00
0-0.25
7. Postflow
0-9.9
X = Setting available.
Weld Time
Crater
Time
Burnback
Time
Preflow
Time
Start
Time
Postflow
Time
Time
Burnback
Postflow
Run-In
Weld
Start
Crater
Trigger
Sequence
End
Preflow
Trigger
Pressed
Released
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS
8-1. Optional Dual Schedule Switch Diagrams
1
2
Maint 2P (Maintained-Contact
2-Pole Switch)
1
2
Maint 1P (Maintained-Contact
1-Pole Switch)
1
2
DSS-9
1
DSS-8
1
. Will not function with trigger
hold and dual schedule. A
DSS-9 is recommended for
this application.
2
2
3
TR
B
A
3
4
A
4
B
OM-1500-7 Page 29
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8-2. Diagnostics
1
2
3
LED3 On Right Side Motor
Control Board PC1
2
3
LED3 On Left Side Motor
Control Board PC101
LED4 On Dual Board PC70
. There is a two-position DIP
switch S1 located on motor con-
trol boards PC1 and PC101.
These switches are factory-set
in the off position and must re-
main in that position for the unit to
operate correctly.
1
803 063-A
Left Side Motor Control Board PC101
ERR
ERR
ERR
TCH1
ERR
COM1
Indicates a com-
munication error.
TRG1
Indicates a trigger
error.
MTR1
Indicates a motor
error.
Indicates a
tachometer error.
. Note: The error messages
are shown on the upper
and lower displays to indi-
cate specific errors. Ex-
planations are in the text
below:
Right Side Motor Control Board PC1
ERR
ERR
ERR
ERR
COM2
Indicates a com-
munication error.
TRG2
Indicates a trigger
error.
TCH2
MTR2
Indicates a motor
error.
Indicates a
tachometer error.
Dual Board PC70
ERR
Indicates a
communication
COM3
error.
LED3-Related Error Indications
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach Error
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The user may
continue to weld with this error. The motor
speed is regulated through the monitoring of
voltage and current.
Error conditions are indicated by LED3 on
PC1, PC101, and LED4 on PC70. To view
LED3, 4 turn Off unit, remove wrapper, and
turn unit On.
The LED blinks in a 2.5 second cycle. The
number of blinks in this period indicates the
type of error.
The priority of the errors is related to the num-
ber of blinks indicating the error. The more
blinks, the more severe the error (motor error
is top priority). A higher priority error overrides
a lower one (if a motor error and a communica-
tion error existed, the light would blink four
times for the motor error).
Since blink On time and blink Off time are
equal in a four-blink cycle, the four−blink se-
quence appears as a constant blink.
4 blinks = Motor Error
• The communication error occurs 2.5 sec-
onds after a loss of communication between
the motor and the Front Panel board or Dual
board. The user may continue to weld with
this error.
• The motor error indicates that the motor
has been drawing too much current for too
long.
• The trigger error occurs if the user has the
trigger held for more than two minutes with-
out striking an arc (providing current over-
ride is not enabled), or if the user holds the
trigger past the postflow phase in a timed
weld. This error also occurs if the trigger is
held when the feeder is powered up. The er-
ror may be cleared by releasing the trigger.
OM-1500-7 Page 30
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8-3. Diagnostics For User Defined Options
1
2
Front Panel
Front Panel Board PC20
User Defined Shutdown Error
Messages (Additional hardware
required for these to be functional)
1
If OPT1 and/or OPT2 are enabled
without additional hardware setup,
the following error messages will be
displayed on the front panel meters.
OPT1 and/or OPT2 must be dis-
abled.
2
rect setup procedures.
803 071
ERR
ERR
OPT1
OPT2
Indicates a User Defined
Option Error
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Routine Maintenance
. Maintain more often
Disconnectpower
before maintaining.
during severe conditions.
3 Months
Clean and
tighten
Repair or
replace
cracked
weld
Replace
unreadable
labels.
weld
terminals.
cable.
Replace
cracked
parts.
Check
14-pin cord.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
Clean
drive rolls.
Or
monthly.
OM-1500-7 Page 31
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9-2. Troubleshooting
Disconnect power before troubleshooting.
Remedy
Trouble
Wire feeds, shielding gas flows, but elec- Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see
Wire feeder is on, meter(s) do not light Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
Electrode wire feeding stops or feeds er- Check gun trigger connection. See gun Owner’s Manual.
ratically during welding.
Check gun trigger. See gun Owner’s Manual.
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.
Motor runs slowly.
Check for correct input voltage.
Wire does not feed until trigger is pulled, Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
but continues to feed after trigger is re-
leased, and trigger hold is not on.
Gas valve in feeder is rattling loudly Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
along with possible erratic or slow wire
feed speed.
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-1500-7 Page 32
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Notes
OM-1500-7 Page 33
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204 144-C
OM-1500-7 Page 35
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Item
No.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 159 647 . . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . 159 646 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 159 360 . . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 4 . . . . . . . . . . . . . . . 201 762 . . Drive Assy, Wire S/L 4 Roll W/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 208 831 . . Drive Assy, Wire S/L 4 Roll Lo-Speed W/Tach . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 201 763 . . Drive Assy,Wire S/L 4 Roll Hi−Speed W/Tach . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 143 160 . . Hub+Spindle Assy, (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 180 571 . . . . Shaft, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . Spring, Cprsn .970 Od X .120 Wire X 1.250pld . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . Washer, Flat Stl Keyed 1.500dia X .125thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . Washer, Fbr .656 Id X 1.500 Od X .125thk . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 071 730 . . . . Tubing, STL .875 Od X 12Ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . 135 205 . . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 141 411 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 204 484 . . Extension, Dual Clamp L.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 208 338 . . Extension, Dual Clamp R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 156 243 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . 145 639 . . Strip, Buna−n .062 X 3.000 X 4.000 Compressed Sht . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 139 226 . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 134 306 . . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box (Refer to Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 201 768 . . Drive Assy, Wire R 4 Roll W/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 208 830 . . Drive Assy, Wire R 4 Roll Lo-Speed W/Tach . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 201 769 . . Drive Assy,Wire R 4 Roll Hi−Speed W/Tach . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 164 059 . . Hose, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1500-7 Page 37
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. Hardware is common and
not available unless listed.
9
11
14
8
7
1
15
10
13
12
28
16
9
2
6
4
3
27
26
5
17
25
24
19
18
20
8
21
22
23
803 051-C
Figure 11-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 204 722 . . Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 134 464 . . Label,Warning General Precautionary Static&wire Fe . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 936 . . Label,Warning General Precautionary Wordless Ce Wf . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 206 764 . . Panel, Pc Card Front (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 200 153 . . . . Overlay, Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . PC21 . . . . . 200 693 . . . . Circuit Card Assy,Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . PC20 . . . . . 210 683 . . . . Panel, Pc Card Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S1 . . . . . . 111 997 . . Switch, Rocker Spst 10A 250vac On-Off Visi Red Rock . . . . . . . . . . . . . 1
. . . 7 . . . . PC70 . . . . . 220 903 . . Circuit Card Assy, Dual W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . PC1,101 . . . 217 898 . . Circuit Card Assy, Motor Control W/Program . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . 030 170 . . Bushing,Snap−in Nyl .750 Id X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . . 000 527 . . Blank, Snap−in Nyl .875 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 200 196 . . Cable, Power 11.5ft 8/c 2-14ga 6-18ga (consisting of) . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 139 041 . . . . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 163 519 . . . . Cable, Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Ft (3.5 m)
. . . 14 . . . . . . . . . . . . . . . 079 739 . . . . Conn, circ cpc clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . PLG12 . . . . 141 162 . . . . Housing Plug+Pins, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG52 . . . . 174 823 . . . . Housing Plug Pins+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG74 . . . . 115 093 . . . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 605 227 . . Nut, 750−14 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . GS1,101 . . . 228 035 . . Valve, 34VDC 1way .750−14 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . 010 494 . . Bushing, Snap−in Nyl 1.375 Id X 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 134 201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . 17
. . . 20 . . . . . . . . . . . . . . . 204 721 . . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-1500-7 Page 38
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box (Continued)
. . . 21 . . . . . . . . . . . . . . . 206 765 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 206 771 . . Nameplate, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 206 515 . . Nameplate, Lower (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . S2,102 . . . . 200 295 . . Switch, rocker spdt 15A 12V (on)−off−(on) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . S100 . . . . . 201 641 . . Switch, rocker spdt 15A 12V (on)−off−(on) W/leds . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 213 134 . . Knob, Encoder 1.670 dia x .250 id push on w/spring . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 207 745 . . Nameplate, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 207 744 . . Nameplate, Upper (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . RC13,113 . . . 048 282 . . RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 28 . . . . . . . . . . . . . . . 211 989 . . Fitting, w/screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
Dia.
Part
Mkgs.
No.
Description
Quantity
Harness Connectors/Receptacles
. . . . . . . . PLG6,106 . . . 115 094 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG10,110 . . 130 203 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG72 . . . . 115 092 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4,104 . . . 136 810 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . PLG11, 21,71,111 131 055 . . Housing Rcpt+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PLG1,77,78,79,101 202 592 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG3,75,76,103 115 093 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG51 . . . . 174 824 . . Housing Plug Pins+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . PLG7,27,67,107 115 091 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG73 . . . . 148 439 . . Housing Plug Pins+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG17,70 . . . 158 719 . . Housing Plug+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG117 . . . 165 404 . . Housing Rcpt+Skts, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-1500-7 Page 39
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13
. Hardware is common and
19
not available unless listed.
11
14
15
16
See Table 11-1 For
17
11
Drive Roll & Wire Guide Kits
18
9
7
8
6
5
4
19
3
2
12
1
20
10
21
22
37
23
24
25
26
36
35
34
27
33
28
6
32
29
5
30
31
4
3
2
1
803 790-A
Figure 11-3. Drive Assembly, Wire
Item
No.
Dia.
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 . . M1,101 . . . . . 201 230 . . Motor, Gear 1/8hp 24vdc Standard Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . M1,101 . . . . . 201 231 . . Motor, Gear 1/8hp 24vdc High Speed (optional) . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . M1,101 . . . . . 207 892 . . Motor, Gear 1/8hp 24vdc Low Speed (optional) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 491 . . . . Kit, Brush Replacement (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 492 . . . . . Cap, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . *153 493 . . . . . Brush, Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 184 136 . . . . Kit, Brush Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 155 098 . . Kit, Cover Motor Gearbox (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 550 . . . . Cover, Motor Gearbox (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 155 099 . . . . . Gasket, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 155 100 . . . . . Screw, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . 154 031 . . . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 133 493 . . . . Ring, Rtng Ext .250 Shaft Grv X .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 203 642 . . Pressure Arm, R & Vert L 4 Roll (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 203 631 . . Pressure Arm, S/L & Vert S/R 4 Roll (consisting of) . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 203 641 . . . . Washer, Flat Indicator Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 182 415 . . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 203 640 . . . . Knob, W/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-1500-7 Page 40
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Drive Assembly, Wire (continued)
. . . 14 . . . . . . . . . . . . . . . 182 156 . . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . 182 155 . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . 132 746 . . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . . 203 633 . . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 203 632 . . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 133 739 . . . . Washer, Flat Buna .375 Id X .625 Od X .062thk . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . . 203 637 . . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . PC51,151 . . . 201 225 . . Circuit Card, Digital Tach (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG5 . . . . . 131 204 . . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 604 311 . . . . Grommet, Rbr .250 Id X .375mtg Hole .062 Groove . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 132 611 . . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 603 115 . . Weather Stripping, Adh .125 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 167 387 . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . . 168 825 . . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 133 308 . . Ring, Retaining Ext .375 Shaft X .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 134 834 . . Hose, Sae .187 Id X .410 Od (order by ft) . . . . . . . . . . . . . . . . . . . . 2Ft (0.6 m)
. . . 27 . . . . . . . . . . . . . . . 149 959 . . Fitting, Brs Barbed M 3/16tbg X .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 179 265 . . Adapter, Gun/Feeder LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 179 264 . . Adapter, Gun/Feeder RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 108 940 . . Screw, Cap Stl Hexhd .250-20 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 30 . . . . . . . . . . . . . . . 604 538 . . Washer, Flat Stl Sae .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 151 437 . . Knob, Plstc T 1.125 Lg X .312-18 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 151 290 . . Screw, Mach Stl Hexwhd 10-32 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . . 179 277 . . Cover, Drive Roll (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 937 . . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 601 872 . . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 602 213 . . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . 602 243 . . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . 601 966 . . Screw, Cap Stl Hexhd .375-16 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1500-7 Page 41
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” 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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
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 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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