OM-220 390F
Processes
2006−08
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Wire Feeder
™
Axcess Wire Feeder
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4. 9-Pin Network Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-5. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-6. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-7. Feeder Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-8. Dual Schedule Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-3. Front Panel Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-4. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-7. Feeder Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-8. Adjust Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-9. Process Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-10. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-11. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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
MILLER Europe 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:
AxcessE Wire Feeder
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
Arc Welding Equipment − Part 5: Wire Feeders. IEC 60974-5 Ed. 1
dec_wire_2/04
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
Safety Standards.
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Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
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Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
During operation, keep everybody, especially children, away.
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Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
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Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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FUMES AND GASES can be hazardous.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
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If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
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Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
OM-220 390 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
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Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
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Wear approved safety glasses with side shields under your
helmet.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
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Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
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Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
NOISE can damage hearing.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
damagehearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Wear approved ear protection if noise level is
high.
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Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
CYLINDERS can explode if damaged.
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Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
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Do not use welder to thaw frozen pipes.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
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Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
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Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
FLYING METAL can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
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OM-220 390 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
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Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
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Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
OVERUSE can cause OVERHEATING
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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Do not block or filter airflow to unit.
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The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
STATIC (ESD) can damage PC boards.
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Have the installation regularly checked and maintained.
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Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
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ARC WELDING can cause interference.
MOVING PARTS can cause injury.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagneticallycompatible.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
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To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
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Do not press gun trigger until instructed to do
so.
Be sure this welding machine is installed and grounded
according to this manual.
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Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
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Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-220 390 Page 3
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1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101(phone: 617−770−3000, website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-220 390 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som _3/05
Y
Avertissement: se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
Symbole graphique d’avertissement ! Attention ! Cette pro-
cédure comporte des risques possibles ! Les dangers éven-
tuels sont représentés par les symboles graphiques joints.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Y
Indique un message de sécurité particulier
. Signifie NOTE ; n’est pas relatif à la sécurité.
2-2. Dangers relatifs au soudage à l’arc
Y
Les symboles représentés ci-dessous sont utilisés dans ce manuel
pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions en
matière de sécurité indiquées ci-dessous ne constituent qu’un
sommaire des instructions de sécurité plus complètes fournies
observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonction-
ner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les per-
sonnes, notamment les enfants de l’appareil.
D
Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement en
place.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
D
D
D
D
Y
Y
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
D
D
D
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
D
D
Ne pas toucher aux pièces électriques sous tension.
Porter des gants isolants et des vêtements de protection secs et sans
trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou des
tapis assez grands afin d’éviter tout contact physique avec la pièce à
couper ou le sol.
Ne pas se servir de source électrique à courant électrique dans les zo-
nes humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère né-
cessaire, se servir de la fonction de télécommande si l’appareil en est
équipé.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
D
D
Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions indi-
quées dans la partie Entretien avant de toucher les pièces.
D
D
D
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereuse pour la santé.
D
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si l’on
porte des vêtements mouillés ; sur des structures métalliques telles que
sols, grilles ou échafaudages ; en position coincée comme assise, à ge-
noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC
à tension constante (à fil), 2) un poste à souder DC manuel (électrode)
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des
situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer le poste correctement et le mettre à la terre convenablement
selon les consignes du manuel de l’opérateur et les normes nationales,
provinciales et locales.
D
D
D
D
Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-
peurs.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu-
vé.
Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un sur-
veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-
quant des blessures ou des accidents mortels. S’assurer que l’air de
respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz haute-
ment toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-
vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
portant un respirateur à alimentation d’air. Les revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxi-
ques en cas de soudage.
D
D
D
D
D
D
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer
que le fil de terre du cordon d’alimentation est bien raccordé à la borne
de terre du sectionneur ou que la fiche du cordon est raccordée à une
prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
OM-220 390 Page 5
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LES RAYONS D’ARC peuvent entraî-
ner des brûlures aux yeux et à la peau.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-
quer des brûlures dans les yeux et sur la peau.
D
Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D
Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
d’air homologué.
Des étincelles sont projetées pendant le soudage.
D
Porter un casque de soudage approuvé muni de verres filtrants ap-
proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous vo-
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
tre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
D
Ne pas toucher des parties chaudes à mains
nues.
D
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D
D
Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
Porteurs de stimulateur cardiaque, rester
à distance.
d’étincelles,des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrodeavec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
D
Les porteurs d’un stimulateur cardiaque doi-
vent d’abord consulter leur médecin avant de
s’approcherdes opérations de soudage à l’arc,
de gougeage ou de soudage par points.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi-
gneusementavec des protections homologuées.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa-
rés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une longue
distance par des chemins inconnus éventuels en provoquant des
risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
En cas de non-utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
D
D
D
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de soudage,
les manipuler avec précaution.
D
D
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
ve, des chocs mécaniques, des dommages physiques, du lai-
tier, des flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support sta-
tionnaireou dans un porte-bouteilles pour les empêcher de tom-
ber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
D
D
D
D
D
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
D
Avant de souder, retirer toute substance combustible de ses poches
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
telles qu’un allumeur au butane ou des allumettes.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifi-
que ; les maintenir ainsi que les éléments associés en bon état.
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
Le couvercle du détendeur doit toujours être en place, sauf lors-
que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
Utiliser les équipements corrects, les bonnes procédures et suf-
fisammentde personnes pour soulever et déplacer les bouteil-
les.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécuri-
té.
Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un ex-
tincteur à proximité.
D
D
DES
PARTICULES
VOLANTES
peuvent blesser les yeux.
D
Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage
génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D
D
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
OM-220 390 Page 6
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Ne pas installer l’appareil à proximité de
produits inflammables.
D
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
D
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D
Lire le manuel d’utilisation avant d’utiliser ou
d’intervenirsur l’appareil.
D
D
Utiliser uniquement des pièces de rechange
Miller/Hobart.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
D
Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipe-
ments de radio-navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
D
D
Prévoir une période de refroidissement ;
respecter le cycle opératoire nominal.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’instal-
lation.
L’utilisateurest tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenirsoigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
distance correcte et utiliser une terre et un blindage pour réduire
les interférences éventuelles.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Veiller à ce que tout l’équipement de la zone de
D
Ne pas s’approcher des organes mobiles.
soudage soit compatible électromagnétiquement.
D
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
ment électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentaires telles que le déplacement du poste, l’utilisation de
câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en enga-
geant le fil de soudage.
2-4. Proposition californienne 65 Avertissements
Y
Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :
fumées et des gaz qui contiennent des produits chimiques dont
Y
Les gaz d’échappement des moteurs contiennent des produits
l’État de Californie reconnaît qu’ils provoquent des malformations
congénitales et, dans certains cas, des cancers. (Code de santé et
de sécurité de Californie, chapitre 25249.5 et suivants)
chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres pro-
blèmes de procréation.
Pour les moteurs diesel :
Y
Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des can-
cers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Y
Les gaz d’échappement des moteurs diesel et certains de leurs
composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou au-
tres problèmes de procréation.
OM-220 390 Page 7
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2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone
:
:
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou
à
Toronto 416-747-4044, site Internet
ternet : www.global.ihs.com).
www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000,site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101(téléphone : 617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220,site Internet : www.osha.gov).
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
champs magnétiques et électriques.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
Le courant de soudage, pendant son passage dans les câbles de souda-
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
certain souci à propos de tels champs. Cependant, après avoir examiné
votre corps.
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
4. Garder le poste de soudage et les câbles le plus loin possible de
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
vous.
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ».
5. Connecter la pince sur la pièce aussi près que possible de la sou-
Toutefois, des études sont toujours en cours et les preuves continuent à
dure.
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-
les procédures suivantes :
cin approuve, il est recommandé de suivre les procédures précédentes.
OM-220 390 Page 8
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SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Drive rolls can injure fingers
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
1.1
2.1
1.2
1.3
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
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
3.1
4.1
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.
6
4
Arc rays can burn eyes and
injure skin.
+
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-220 390 Page 9
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3-2. Manufacturer’s Rating Label For CE Products
For label location
225 622-A
3-3. Symbols And Definitions
Some symbols are found only on CE products.
NOTE
Direct Current
(DC)
Output
Amperes
Volts
V
A
Degree Of
Protection
Duty Cycle
Wire Feed
Percent
X
I1
IP
Cold Jog (Inch)
Towards
Workpiece
Input
Purge By Gas
Fast
Slow
Constant Current
Trigger Hold Off
Circuit Breaker
Trigger Hold On
Constant Voltage
Rated Welding
Current
Increase
I2
U2
Conventional Load
Voltage
Read Instructions
Primary Voltage
Locked
U1
Primary Current
Wire Type
Sequence
Gas Type
Program
Process
Time
Variable
Inductance
Trigger Hold On
Indicator Light
Trigger Hold
Off Indicator Light
Arc Control
Trigger Control
Three Phase
Single Phase
Line Connection
OM-220 390 Page 10
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SECTION 4 − INTRODUCTION
4-1. Specifications
Type of Input
Power
Welding Power
Source Type
Wire Diameter
Range
Welding Circuit
Rating
Overall
Dimensions
Wire Feed Speed Range
Weight
40 Volts DC
10 Amperes
Axcess Series
Standard: 40 To 1400 ipm (1.0
To 35.6 mpm)
.030 To 1/8 in
100 Volts,
300 Amperes,
100% Duty
Cycle
Length: 27 in (686
mm)
46 lb
(20.9 kg)
(0.8 To 3.2 mm)
Width: 12-1/2 in
(318 mm)
Max Spool
Weight: 60 lb (27
kg)
Height: 14-1/2 in
(368 mm)
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Y
Do not move or operate
unit where it could tip.
Movement
Tipping
2
OR
1
Location
Y
Do not stack units. Beware of
tipping.
Y
Special installation may be required where gasoline or volatile
liquids are present − see NEC Article 511 or CEC Section 20.
1
Lifting Forks
Use lifting forks to move unit.
4
Extend forks beyond opposite side
of unit.
2
Hand Cart
Use cart or similar device to move
unit.
3
3
Rating Label
Use rating label to determine input
power needs.
18 in
(460 mm)
4
Line Disconnect Device
Locate unit near correct input
power supply.
18 in
(460 mm)
loc_2 3/96 - Ref. 803 502-B
OM-220 390 Page 11
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5-2. Connection Diagram
1
2
3
4
5
6
7
8
Welding Power Source
Wire Feeder
Gas Cylinder
3
Gas Hose
Network Feeder Cable
Negative (−) Weld Cable
Workpiece
4
Voltage Sensing Lead
Recommendedfor Accu-pulse and
RMD (optional).
5
. Positive (+) voltage sensing
lead is contained in the motor
cable.
2
1
9
Positive (+) Weld Cable
7
9
8
6
Ref. 801 915 / Ref. 803 501-B
OM-220 390 Page 12
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5-3. Rear Panel Connections And Rotating Drive Assembly
1
2
9-Pin Network Receptacle
Shielding Gas Valve Fitting
Requires fitting with 5/8-18 right-
hand threads. Connect customer-
supplied gas hose.
3
4
5
6
Weld Cable Terminal
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
7
Rating Label Location
To rotate the drive assembly,
loosen drive assembly rotation
knob, rotate drive assembly, and
tighten knob.
7
1
2
3
4
5
6
Tools Needed:
9/16, 5/8 in
3/16 in
802 825-A / 803 503-B
OM-220 390 Page 13
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5-4. 9-Pin Network Receptacle Information
Pin
Pin Information
9
A
B
C
D
E
F
Capacitor C1 to ground
Shield
Volt sense
F
I
G
Can low
E
H
Can high
D
A
+24 volts dc common
+ 24 volts dc
C
B
G
H
Motor voltage +40 volts dc common
I
Motor voltage +40 volts dc
5-5. Gun Recommendation Table
Process
Gun
GMAW − Hard or Cored Wires
400, 500, And 600 Amp
Air-Cooled Guns
GMAW − Pulse
Water-Cooled Guns
OM-220 390 Page 14
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5-6. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Indicator
Scale
Pressure
Adjust
Rear
Rolls
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Drive Rolls
Gun Cable
Tools Needed:
3/16, 5/64 in
15/16, 3/8 in
End Of Liner
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
liner for the welding wire size. When
installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If
contact tip is completely blocked, wire
should slip at the feeder (see pressure
adjustment above).Cut wire off. Close
cover.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A
OM-220 390 Page 15
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5-7. Feeder Display At Power Up
1
2
Upper Display
Lower Display
1
2
t
V
A
ProcessꢀꢁSetup
Adjust
FeederꢀꢁSetup
Upper Display
Net
Voltage Range
Power Source
Lower Display
Wait
DTEC
OFF
Axcess
Axcs
300/450/675
10
44
219 711-A
5-8. Dual Schedule Switch Option
1
Maint 2P (Maintained-Contact
2-Pole Switch)
DSS-9M Part# 041 793
1
2
DSS-9M 1
2
1
A
B
3
4
OM-220 390 Page 16
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SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:
General Terms:
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases
the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by
volts in MIG programs.
Trigger Control
Selecting Trigger Control allows activating trigger functions such as DS, TH, 4T, TDS, and TPS.
Dual Schedule allows selecting a pair of programs that can be used together.
DS (Dual Schedule)
TH (Trigger Hold)
Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger
hold mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed
again.
4T
4T allows the operator to select between weld parameters and crater parameters using the gun
trigger. Crater time must be set for at least 0.2 seconds to make this function operational. If gun
trigger is released during welding, unit goes into trigger hold, then pressing and holding trigger again
causes unit to stay in crater until trigger is released and crater parameter times out.
TDS (Trigger Dual Schedule)
TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS
mode, momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected
weld programs.
TPS (Trigger Program Schedule)
TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily
pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total
of 8 programs.
Program
Process
MIG
Eight active slots for selection of various processes, wire type, and parameters.
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
CV weld process with individual settings of voltage and wire speed.
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as
factory taught data. Adaptive method is controlled by frequency adjustment.
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and
backgrounds. Adaptive response is controlled by peak and minimum current levels. Benefits are
shorter arc lengths, better puddle control, more tolerant of tip-to-work variation, less audible noise, no
arc wandering, allows weld to fill in at toes increasing travel speed and deposition, and more tolerant
to poor fit up and gaps.
Accuspeed
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is de-
signed to be tight and fast. Front panel display is ACCU − SPED.
AccuCurve
CV Pulse process using a pulse waveform with modified curves at particular locations within the wa-
veform. Has a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
RMD (optional)
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of
RMD are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat
input into workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge
materials.
Wire Type
Gas Type
Selection of wire type by alloys and classification.
Selection of shielding gas being used in application.
Selection procedure for entering program.
Process Set Up
Program Load
Volts
Enters selected program information into program slot.
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of
weld.
Time
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in
the Arc On and Analog input or the Arc On and No Analog input modes).
Arc Length
WFS
Distance from end of wire electrode to workpiece.
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage
setting. In pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power
level on wire electrode (one knob control).
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control
Allows setting of inductance in MIG mode. In pulse and Accu-pulse mode, this adjustment changes
the arc cone by adjusting the preprogrammed factory pulse data. In RMD (optional), this control will
affect the in much the same way as inductance.
Inductance
Adjust
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit
transfers per second (provided no other changes are made) and increase the arc-on time. The
increased arc-on time makes the welding puddle more fluid.
Control knob used to change or set parameters and functions.
OM-220 390 Page 17
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General Terms:
Sequence
Preflow
Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters.
Setting a time value for gas flow prior to arc start.
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only
adjustable with the optional PDA with File Management/WaveWriter software).
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.
Setting a time value for gas flow after arc end.
Postflow
Feeder Set Up
Auto Thread
Allow selection of Sequence and trigger functions.
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously
will automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be
changed using a PDA with File Management/WaveWriter software). Pressing jog, purge, or trigger
switch will terminate the auto-threading feature.
6-2. Power Switch
1
Power Switch
1
803 504-B
OM-220 390 Page 18
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6-3. Front Panel Sections
See
Section 6-5
See
See
t
V
A
Adjust
ProcessꢀꢁSetup
FeederꢀꢁSetup
See
See
See
219 711-A
OM-220 390 Page 19
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6-4. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
3
Program Push Button
Program Push Button LED
The LED lights to indicate that
programs can be changed using
the Adjust knob.
1
2
Momentarily press button to
illuminate LED. To change the
program number, rotate Adjust knob
to select one of eight programs.
3
Pressing and holding the push
button will display current wire size,
wire type and process.
To reset feeder to factory settings,
turn power source off for 10
seconds. Press and hold button in
on power up, wait until top display
shows RST and bottom display
shows NO before releasing button.
Feeder Set Up button LED will
begin flashing. Turn Adjust knob to
change bottom display to show
YES, then press Feeder Set Up
button to confirm selection. The top
display will show CYCL and the
lower display will show PWR. Turn
welding power source power off for
10 seconds, then turn power back
on again.
6-5. Upper Display
3
2
1
4
V
5
1
Upper Display
illuminates to indicate that information
displayedcan be changed by the Adjust knob.
Adjust knob. The preset values will be
displayed while the knob is being rotated
and return to displaying actual values
when adjustment is completed.
The upper display at idle (not welding) shows
preset volts with process selection MIG or Arc
Adjust for all other processes. When welding,
the display shows actual voltage. The display
will show actual voltage for approximately 3
seconds after welding stops before returning
to preset value.
4
Volts LED
Indicates a voltage value is being displayed,
preset voltage in MIG when not welding and
actual voltage while welding.
To activate Carbon Arc Cutting (CAC), press
and hold the upper display push button in on
power up. CAC will appear on the upper
display and NO will appear on the lower
display. Rotate adjust knob to YES on the
lower display, and press the flashing Feeder
Set up push button . CYCL will appear on the
upper display and PWR will appear on the
lower display. Turn welding power source off
5
Arc Adjust LED
Indicates that displayed value is an arc length
value when the process is Pulse, Accu-pulse,
or RMD (optional).
2
Upper Display Push Button
Press the button to illuminate the LED and
allow changing information in the display.
. At any time while welding, the display
3
Upper Display Push Button LED
allows adjustment of the weld voltage or and back on again to enable the Carbon Arc
The upper display push button LED
arc adjust preset values by turning the Cutting process selection.
OM-220 390 Page 20
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6-6. Lower Display
5
7
6
t
1
2
A
3
4
1
Lower Display
4
Arc Ctl (Arc Control) LED
During a welding program operation, it is
possible to change WFS (wire feed speed) by
using the Adjust knob regardless of the active
program sequence that appears on the dis-
play.
LED illuminates to indicate that inductance
(MIG) or ARC [Pulse, Accu-pulse, or RMD
(optional)] is being displayed and can be
adjusted using the Adjust knob.
The lower display shows WFS (wire feed
speed), AMPS (amperage), ARC CTL (arc
control), or Time. The feeder displays only
preset wire speed at idle (not welding). While
welding, the average amperage is displayed.
The lower display shows welding sequence
time when the Time LED is illuminated.
5
Time LED
When the Arc Ctl LED is illuminated, it is
possible to change values while welding by
using the Adjust knob. To return to actual
values on the display, exit the Arc Ctl display.
LED illuminates to indicate that a time value is
being displayed for a sequence function and
can be adjusted using the Adjust knob.
2
WFS (Wire Feed Speed) LED
6
7
Lower Display Push Button
Lower Display Push Button LED
. The lower display push button has
additional functions when entering the
sequence and trigger control functions
LED illuminates to indicate the preset wire feed
value is being displayed and can be adjusted
using the Adjust knob.
Pressing the button illuminates the LED and
selects either WFS or Arc Ctl value for
changing using the Adjust knob.
To select Arc Ctl, press and hold lower display
button for 2 seconds. The top display will show
either INDU for a MIG program or ARC for
Pulse, Accu-pulse, or RMD (optional). To exit
3
Amps LED
LED illuminates to indicate the average
amperage is being displayed while welding
and for 3 seconds after welding is terminated. Arc Ctl or INDU, either press the upper display
The amperage must be above a minimum
value of 25 amps for this function to operate.
push button or press and hold the lower display
push button for 2 seconds.
OM-220 390 Page 21
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6-7. Feeder Set Up Push Button
3
Start
Time
4
Crater
Time
Preflow
Time
Postflow
Time
1
2
Sequence Diagram
FeederꢀꢁSetup
1
2
Feeder Set Up Push Button LED
Feeder Set Up Push Button
the Upper Display push button.
trigger control selections. Use the Adjust
knob to cycle through the trigger control
methodsas follows: DS, TH, TDS, TPS, and
lower display will show the current state of
each trigger control method as being on or
off. Not all trigger control methods are
compatible with each other, therefore,
turning on certain trigger selections will
cause other trigger selections to turn off.
• The Sequence option STRT and CRTR will
have additional parameter settings. By
pushing the Lower Display push button a
second time, while STRT or CRTR appear
in the upper display, allows entering voltage
(MIG) or Arc Adjust [Pulse, Accu-pulse, or
RMD (optional)]. Use the Adjust knob to
change the values indicated by the flashing
LED for either Volts or Arc Adjust. Pressing
the Lower Display push button a third time
will activate the WFS setting for either STRT
or CRTR and the WFS LED will begin
flashing. Use the Adjust knob to change the
WFS value.
• Press button to choose Sequence. Feeder
Set Up push-button LED will illuminate.
3
Sequence LED
• When the Feeder Set Up button is pressed
once, the Sequence LED will illuminate and
the upper display will show sequence
options. Use the Adjust knob to select PRE
(preflow), STRT (start), CRTR (crater), or
POST (postflow).
• Press the lower display push button to
illuminatethe push-button LED and enable
the use of the Adjust knob to allow turning
selected trigger control methods on or off. If
trigger hold is set to on, the Trigger Hold
LED will illuminate.
• Press the lower display push button and the
Lower Display push-button LED will
illuminateas well as the lower display. The
Time LED will automatically begin flashing
indicating that a time value can be entered
by turning the Adjust knob. By entering a
time value the sequence state will become
• Pressing the Feeder Set Up button two
more times will exit the Sequence menu and
return the system to standby mode.
. Trigger Hold is automatically set to On
with the 4T trigger selection. This is part
of the 4T function.
4
Trigger Control LED
active. To turn off a sequence state, change • Press the Feeder Set Up button twice and
the time value to OFF. To step back for
selecting another sequence option, press
the Trigger Control LED will illuminate, and • Press the Feeder Set Up button a third time
the upper display will show the different
to cycle back to standby mode.
6-8. Adjust Knob
1
Adjust Knob
The Adjust knob is used to change
functions and parameters. Refer to
the front panel sections for
information regarding use of this
control.
1
Adjust
OM-220 390 Page 22
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6-9. Process Set Up Push Button
1
2
3
Process Set Up Push Button
Process Set Up LED
3
Program Selection LEDs
2
1
ProcessꢀꢁSetup
• Press the Process Set Up push button the • Pressing the Process Set Up push button a • If a custom program is loaded using an
first time will illuminate the button LED and
the Process LED. The upper and lower
displays will be used for Accu-pulse and
only the lower display for MIG, Pulse and
RMD (optional) to show the current process
installed in this program. To change
process, turn the adjust knob.
fourth time will keep Wire Type LED lit and
the upper display will show wire size. The
upper display push button will be flashing
indicating that turning the Adjust knob will
select wire sizes available for that particular
process and wire type.
• Pressing the Process Set Up push button a
fifth time will illuminate the Gas Type LED
and the lower display will show GAS and the
upper display will show gas selection (see
gas type selection, turn the Adjust knob.
• If any of the Process, wire type, alloy type,
wire size, or gas type was changed, then
pressing the Process Set Up push button a
sixth time will show PROG in the upper
display and LOAD in the lower display. The
new program would be loaded for that
particular program in slot 1 thru 8. If no
changes were made to any setup items, no
program will be loaded, and unit will return
to standby mode.
optional PDA with File Management
software, the Program Display will have a
“C” in front of the program number. This
indicates that the program is not a factory
default program and has been modified. By
selecting or changing any process variable
and performing a program load will restore
the program back to the factory default
program.
• Pressing the Process Set Up push button a
second time will illuminate the Wire Type
LED and the lower display will show wire
types available for selected processes (see
selection, turn the Adjust knob.
• Pressing and holding the Process Set Up
push button in on power up allows viewing
the software revisions of each circuit board
in the system. The top display shows the
board (PCM, UIM, WFCM, and AIM
(automatedunits only) and the lower display
shows the last 3 digits of the circuit board
part number plus a letter designator. Press
the flashing Feeder Set Up push button to
exit the screen displays and continue the
power up process.
• Pressing the Process Set Up push button a
third time will keep Wire Type LED lit and the
upper display will show wire alloy type (see
push-buttonLED will be flashing indicating
that turning the Adjust knob will change the
alloy type for the selected process and wire
type.
Table 4-1. Welding Wire And Gas Abbreviations*
Wire Description Wire Abbreviation
Alloy Type
Gas Type
100% CO ,
Gas Abbreviation
Steel
STL
E70, E100, E120
CO2
C10
C15
C25
C5
OX5
OX2
2
90% Argon/10% CO ,
2
2
2
2
85% Argon/15% CO ,
75% Argon/25% CO ,
95% Argon/5% CO ,
95% Argon /5% O ,
2
2
98% Argon/2% O
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O
OX2
2
(81Ar/18HE/1CO
Accu-pulse)
Tri Gas
2
90HE/7-1/2Ar/2-1/2CO
Tri Gas
2
MIG/RMD/Accu-pulse)
Cored Tubular Wire
Aluminum
MCOR
ALUM
71, 76, 86R, 409,
439
90% Argon/10% CO
C10
OX2
2
98% Argon/2% O
100% Argon
2
4XXX, 5XXX
ARGN
* Not all wire types may be available with your unit.
OM-220 390 Page 23
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6-10. Jog/Purge
1
2
3
Jog/Purge Push Button
Adjust Knob
Gun Trigger Receptacle
2
3
1
803 505-A
The Jog/Purge switch provides the following
functions:
display. After 3 seconds the weld output • Pressing right side of the Jog/Purge switch
turns off and the wire will feed at 50 ipm for
the next 3 seconds and then ramps up to
700 ipm until trigger is released or 30
seconds elapses. If the gun trigger is still
activated after 30 seconds, the jog
operationis terminated to prevent complete
unspooling of the wire and an “ERR STRT”
message is displayed on the upper and
lower displays. Releasing and pressing the
trigger again will clear the error.
allows the operator to purge gas lines before
welding and to preset gas pressure at the
regulator.
• Pressing left side of the Jog/Purge switch
allows the operator to feed wire without
energizing the weld power or gas valve
circuit. The wire will feed at a 50 ipm rate for
3 seconds, then the rate ramps up to 700
ipm until the Jog switch is released.
• This unit is equipped with Auto Thread
capability. By rocking the switch from purge
to jog within 0.5 seconds will automatically
feed wire for a factory default setting of 192
in (4877 mm) of wire before stopping. The
default feed rate is 700 ipm. These settings
can be changed using an optional PDA with
File Management software. Pressing the
Jog/Purge switch or gun trigger during Auto
Threading will terminate the automatic feed
operation.
• The unit also provides the ability to jog the
wire feeder by means of the gun trigger.
When the gun trigger is pressed without
starting an arc, the wire will feed at run-in
speed for the first 3 seconds. During this
time OCV (open circuit voltage) will be
present as indicated on feeder upper
. If Start Error is enabled using an optional
PDA with File Management software, an
“ERR STRT” will occur after the first 3
seconds of run in and jogging from the
trigger is not possible.
OM-220 390 Page 24
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6-11. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
RST
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
V
A
NO
A
. System configuration data will be
lost during the Reset operation.
Setup
Adjust
ArcꢀꢁControl
Enter reset mode by turning power On and pressing
the Program Push Button until the RST NO message
is displayed. RST NO message will not display until
after the power-up sequence is completed
(approximately 20 seconds).
RST
RST
CYCL
V
V
V
A
A
A
YES
YES
PWR
A
A
A
Setup
Setup
Setup
Adjust
Adjust
Adjust
ArcꢀꢁControl
ArcꢀꢁContro
ArcꢀꢁControl
Press the Arc Control button to
confirm the reset.
Cycl Pwr message appears on the display
when programs complete loading.
Rotate Adjust knob to change NO
to YES.
The reset message is displayed for
2 seconds while factory program
settings are being reloaded.
Turn power off, wait 10 seconds, and turn
power back on again to complete the reset
operation.
During the reset mode the following
factory default programs are loaded
into the unit:
. After Reset is complete, be sure to load
appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation
Program 1
Program 2
Program 3
Program 4
Program 5
Program 6
Program 7
Program 8
Pulse
.035 Mild Steel
90% Argon, 10% CO
2
MIG
.035 Mild Steel
75% Argon, 25% CO
2
Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Pulse
.045 Mild Steel
90% Argon, 10% CO
2
MIG
.045 Mild Steel
75% Argon, 25% CO
2
Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Pulse
.052 Mild Steel
90% Argon, 10% CO
2
MIG
.052 Mild Steel
75% Argon, 25% CO
2
198 993 / 803 504-B
OM-220 390 Page 25
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SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence mode, see Feeder
Set Up Push Button in Section
6-7.
Weld Time can only be set by using
an optional PDA with File
Management/WaveWriter software.
Sequence
Parameters
Volts/Arc
Adjust
If time is set to zero in any timed
sequence, the sequence is skipped.
IPM
Seconds
Off-5.0
. Maximum IPM may actually be
lower depending on the process
and wire type selection.
1. Preflow
2. Postflow
3. Start
Off-5.0
Off-5.0
10.0-44.0/
0-99
40-1400
40-1400
10.0-44.0/
0-99
4. Crater
Off-5.0
Weld
Crater
Time
Start
Time
Preflow
Time
Postflow
Time
Sequence
End
Weld
Start
Crater
Postflow
Preflow
Trigger
Released
Trigger
Pressed
OM-220 390 Page 26
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SECTION 8 − MAINTENANCE
8-1. Routine Maintenance
Y
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
n = Check
Z = Change
~ = Clean
l = Replace
Reference
* To be done by Factory Authorized Service Agent
Every
3
Months
l Unreadable Labels
~ Weld Terminals
l Damaged Gas Hose
nl Weld Cables
nl Cords
nl Gun Cables
OR
nl Cracked Parts
Every
6
Months
~ Drive Rolls
~ Inside Unit
OM-220 390 Page 27
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8-2. Diagnostics
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
WFS
ERR
ERR
ERR
TACH
MOTR
STRT
STOP
FLOW
Indicates a
tachometer error.
Indicates a motor
error.
Indicates a wire
feed speed error.
Indicates an arc
start error.
Indicates an arc
stop error.
Indicates a gas
flow error.
ERR
ERR
GND
ERR
ERR
ERR
ERR
ARC
COOL
STUK
TEMP
LINE
Indicates a coolant
flow error.
Indicates a ground
current error.
Indicates a wire
stuck error.
Indicates a
temperature error.
Indicates a line
error.
Indicates an arc
error.
ERR TACH
ERR STOP
ERR STUK
• The tach error occurs 2 seconds after the • The stop error occurs as result of • The stuck error occurs if the welding wire
loss of tachometer feedback. The motor
speed is regulated through the monitoring of
voltage and current. Press Jog/Purge
button to clear error.
obstructions in the wire feed system or a
faulty wire drive system. Check wire feed
and wire drive systems. Press Jog/Purge
button to clear error.
sticks to the workpiece at the end of a weld.
May be caused by poor weld conditions.
The error may be cleared by cutting wire
from workpiece, and pressing the Jog/
Purge button.
ERR MOTR
ERR FLOW
ERR TEMP
• The motor error indicates that the motor
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle. Press Jog/Purge button to clear error.
• The flow error indicates no gas flow to the
gun. The error may be reset by • The temperature error indicates welding
reestablishinggas flow to the gun, and then
pressing the Jog/Purge button.
power source has overheated and
shutdown. The error may be cleared by
allowingunit to cool down, and pressing the
Jog/Purge button.
ERR COOL
• The cool error indicates no coolant flow in
water flow switch option. The error may be
reset by reestablishing coolant flow to the • The line error indicates input power is
gun, and then pressing the Jog/Purge
button.
ERR WFS
ERR LINE
• The wire feed speed error indicates actual
wire feed speed does not match wire feed
speed command. Press Jog/Purge button
to clear error.
outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.
ERR STRT
ERR GND
ERR ARC
• The start error occurs if the user has the
trigger held for more than 3 seconds without
striking an arc, or if a valid arc voltage and
current is not detected. The 3 second arc
start error time can be changed using an op-
tional PDA with File Management software.
• The ground current error occurs if weld
current is detected in the earth ground • The arc error indicates an arc outage
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Press
Jog/Purge button to clear error.
occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.
OM-220 390 Page 28
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WELD
WAIT
MOTR
PLS
OVER
CRNT
LOW
WFS
E
COM
WAIT
STOP
Indicates an
emergency stop error.
Indicates a weld
cycle wait error.
Indicates a motor
Indicates a UIM
Indicates an
overcurrent error.
Indicates a low WFS
command error.
communication error. communication error.
RMD
OVER
AVER
REL
ERR
DONE
TRIG
UNKN
Indicates an arc
error.
Indicates an over
average current error.
Indicates a trigger
closed error.
Indicates an
unknown error.
WELD WAIT
LOW WFS
OVER AVER
• The weld wait error indicates unit was not
ready for a weld sequence. Press Jog/
Purge button to clear error.
• The low wire feed speed error indicates
actual wire feed speed is lower than wire
feed speed command. Check for
obstructions in the wire feed system or a
faulty wire drive system. Press Jog/Purge
button to clear error.
• The over average error indicates that cur-
rent is outside the average range for the set
program parameters. Check and correct
program parameters. Press Jog/Purge but-
ton to clear error.
MOTR COM
• The motor communication error indi-
cates motor board lost data communica-
tions. Press Jog/Purge button to clear error.
REL TRIG
E STOP
PLS WAIT
• The release trigger error indicates the
user held the trigger when starting a weld
program Press Jog/Purge button to clear
error.
• The uim communication error indicates
• The emergency stop error occurs if the
user presses an emergency stop button.
Reset the emergency stop button and press
Jog/Purge button to clear error.
user
interface
board
lost
data
communications. Press Jog/Purge button
to clear error.
OVER CRNT
ERR UNKN
RMD DONE
• The over current error indicates welding
power source primary current is too high.
Check and correct input power. Press Jog/
Purge button to clear error.
• The RMD done error indicates the RMD • The unknown error indicates a malfunc-
demo is completed. Press Jog/Purge button
to clear error.
tion in the system somewhere. Press Jog/
Purge button to clear error.
OM-220 390 Page 29
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8-3. Troubleshooting
Y
Disconnect power before troubleshooting
Remedy
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Electrode wire feeding stops or feeds
erratically during welding.
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Check for correct input voltage.
Motor runs slowly.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
OM-220 390 Page 30
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Notes
OM-220 390 Page 31
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211 005-E
OM-220 390 Page 33
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Item
No.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 159 647 . . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 159 646 . . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 159 360 . . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . . Fig 10-3 . . DRIVE ASSEMBLY, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 141 753 . . HUB & SPINDLE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 180 571 . . . . SHAFT, support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . SPRING, cprsn .970 OD x .120 wire x 1.250pld . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . WASHER, flat stl keyed 1.500dia x .125thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . WASHER, fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 135 205 . . . . NUT, stl slflkg hex reg .625-11 w/nylon insert . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 200 556 . . SUPPORT, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 201 781 . . KNOB, w/extension clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 156 243 . . CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 145 639 . . STRIP, buna N compressed sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 200 552 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 134 306 . . FOOT, rubber 1.250 dia x 1.375 high no 10 screw . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . . . 200 557 . . STIFFENER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . Fig 10-2 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 216 695 . . CAPACITOR, w/terminals (.027UF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
+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-220 390 Page 35
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. Hardware is common and
not available unless listed.
9
7
1
2
10
6
5
11
4
25
8
3
12
15
16
17
14
16
24
13
19
20
21
22
23
803 507-D
Figure 10-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 178 936 . . LABEL, warning general precautionary wordless CE WF . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . +212 781 . . WRAPPER, feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . *211 164 . . PANEL, pc card switch/overlay (including) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 219 711 . . . . NAMEPLATE, overlay/CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . PC5 . . . . . 227 879 . . . . CIRCUIT CARD ASSY, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . PC7 . . . . . 204 049 . . . . CIRCUIT CARD ASSY, user interface module . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 212 808 . . BAFFLE, pc mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . PC6 . . . . *209 681 . . CIRCUIT CARD ASSY, wire feed module . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 211 003 . . ENCLOSURE, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 010 494 . . BUSHING, snap−in nyl 1.375 id x 1.750 mtg hole . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 057 357 . . BUSHING, snap−in nyl .937 id x 1.125 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . RC1 . . . . . 211 018 . . CONNECTOR, circ 97/met 9 pin size 20 rcpt . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG43,46,49,
72 . . . . . . 115 093 . . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 137 761 . . NUT, 750 npt 1.31 hex .27h nyl blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 219 047 . . VALVE, 40 VDC 2 way custom port 1/8 orf w/frict . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 134 201 . . STAND−OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . . . . . . 097 132 . . STAND−OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 16 . . . . . . . . . . . . . . . 211 002 . . ENCLOSURE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC2 . . . . . 212 493 . . CIRCUIT CARD ASSY, motor filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . S1 . . . . . . 213 632 . . SWITCH, rocker dpdt 10A 250VAC/20A 30VAC on-none-on . . . . . . . . . 1
. . . 19 . . . . PC1 . . . . . 212 459 . . CIRCUIT CARD ASSY, trigger filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . RC4 . . . . . 048 282 . . RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 211 085 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-220 390 Page 36
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 22 . . . . . . . . . . . . . . . 211 073 . . NAMEPLATE, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 210 998 . . SWITCH ASSY, jog/purge (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . S2 . . . . . . 200 295 . . . . SWITCH, rocker spdt 15A 12V (on)-off-(on) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 131 056 . . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 131 052 . . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 179 851 . . KNOB, pointer 1.670 dia x .250 id push on w/spring . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 216 866 . . FILTER ASSY, sense lead (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 216 696 . . . . CAPACITOR, w/terminals (.027UF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 038 855 . . . . BLOCK, term 20 amp 2 pole screw term . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 224 383 . . . . RESISTOR, w/terminals (2 K 5 watt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 216 872 . . . . CABLE, volt sense 7 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 213 004 . . . . CABLE, volt sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG47 . . . . 115 094 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG48 . . . . 202 592 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . 136 810 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG81 . . . . 115 092 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG10 . . . . 130 203 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG50 . . . . 136 810 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG44 . . . . 131 058 . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG45 . . . . 188 352 . . HOUSING RCPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG42 . . . . 131 054 . . HOUSING RCPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG40 . . . . 201 665 . . HOUSING RCPT PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 207 676 . . STAND−OFF, no 6-32 x .250 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
+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-220 390 Page 37
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11
. Hardware is common and
18
not available unless listed.
12
13
14
15
Drive Roll & Wire Guide Kits
16
17
9
7
8
6
5
4
3
18
2
1
19
10
15
20
33
21
22
23
24
32
31
30
25
35
26
6
5
29
34
27
28
4
3
2
1
802 950-B
Figure 10-3. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 010 668 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 2 . . . . . . . . . . . . . . . 172 075 . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . . 149 962 . . SPACER, carrier drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . . . . . . . . . . . . 149 486 . . PIN, rotation arm rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 132 750 . . ARM, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 150 520 . . SPACER, flat stl .257 ID x .619 OD x .105 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . 133 493 . . RING, retaining ext .250 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 133 350 . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . M1 . . . . . *213 005 . . MOTOR, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 203 631 . . PRESSURE ARM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 182 415 . . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 203 640 . . . . KNOB, w/extension short pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 203 641 . . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . . 182 156 . . . . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . 182 155 . . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . 132 746 . . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . 203 633 . . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 203 632 . . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 133 739 . . . . WASHER, flat buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . 203 637 . . . . KNOB, w/extension long pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . {229 550 . . ENCODER, quadrature 500PPR incremental 5V shaftless . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 604 311 . . . . GROMMET, rbr .250 ID x .375mtg hole .062 groove . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 603 115 . . WEATHER STRIPPING, adh .125 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 167 387 . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . 168 825 . . DRIVE, pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 133 308 . . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-220 390 Page 38
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 24 . . . . . . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 2ft
. . . . . . . . . . . . . . . . . . . . . 184 685 . . ADAPTER ASSY, gun/feeder LH (including) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 149 959 . . . . FITTING, brs barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 179 265 . . . . ADAPTER, gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 604 538 . . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 151 437 . . . . KNOB, plstc T 1.125 lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 185 624 . . . . SCREW, 010-32 x o.50 hexwhd .40D stl pld slffmg trilob . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . . . 601 872 . . . . NUT, stl hex full fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 602 213 . . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 602 243 . . . . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 601 966 . . . . SCREW, cap stl hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 108 940 . . SCREW, cap stl hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 35 . . . . . . . . . . . . . . . 179 263 . . COVER, drive roll (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 937 . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Table 10-1. Drive Roll And Wire Guide Kits
Wire Size
V-GROOVE
4 Roll Drive
Kit Roll
U-GROOVE
4 Roll Drive
Kit Roll
VK-GROOVE
UC-GROOVE
Inter-
mediate
Guide
Inlet
Guide
4 Roll
Kit
Drive
Roll
4 Roll
Kit
Drive
Roll
Fraction
Metric
.023-.025in.
.030 in.
0.6 mm
0.8 mm
0.9 mm
1.0 mm
150 993
150 993
150 993
150 993
149 518
149 518
149 518
149 518
149 519
149 519
151 024 087 130
151 025 053 695
151 026 053 700
161 189 053 696
151 027 053 697
151 028 053 698
.035 in.
151 036 072 000
151 052 132 958
.040 in.
.045 in.
1.1/1.2 mm 150 994
1.3/1.4 mm 150 994
151 037 053 701
151 038 053 702
151 053 132 957
151 054 132 956
151 070 083 489
151 071 083 490
.052 in.
1/16 in.
1.6 mm
1.8 mm
2.0 mm
150 995
150 995
150 995
149 520
149 520
149 520
151 029 053 699
151 039 053 706
151 055 132 955
151 056 132 959
151 057 132 960
151 072 053 708
(.062 in.)
.068-.072 in.
5/64 in.
(.079 in.)
151 040 053 704
151 041 053 703
151 042 053 705
151 043 053 707
151 073 053 710
151 074 053 709
3/32 in.
(.094 in.)
2.4 mm
2.8 mm
3.2 mm
150 996
150 996
159 997
149 521
149 521
149 522
151 058 132 961
151 059 132 962
151 060 132 963
7/64 in.
(.110 in.)
151 075
053 711
1/8 in.
(.125 in.)
151 076 053 712
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls.
OM-220 390 Page 39
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Effective January 1, 2006
(Equipment with a serial number preface of “LG” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
*
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
*
*
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2006−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2006 Miller Electric Mfg. Co.2006−01
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|