OM-232 386C

Processes

MIG (GMAW) Welding

2008−01

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source and Wire Feeder

R

Millermatic DVI-2

Visit our website at

www.MillerWelds.com

File: MIG (GMAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance.

And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality

System Standard.

exact part you may need to fix the problem.

Warranty and service information for your particular model are also provided.

Working as hard as you do

− every power source from

Miller is backed by the most hassle-free warranty in the business.

Miller Electric manufactures a full line of welders and welding related equipment.

For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 4/05

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2.

Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3.

Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4.

Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5.

Installing Work Cable And Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6.

Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7.

Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8.

Installing MIG Wire Spool and Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9.

Connecting 1-Phase Input Power For 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Electrical Service Guide For 230 VAC

4-11. Extension Cord Data

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Installing Optional Gas Valve, Receptacle, And Barbed Fitting For Optional Spool Gun

4-15. Connecting An Optional Spool Gun

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1.

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2.

Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1.

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2.

Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3.

Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4.

Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

8

9

9

4

5

5

5

1

1

1

3

4

4

13

14

14

15

16

17

11

11

11

11

12

13

26

27

27

30

24

26

26

26

18

18

19

20

21

22

23

23

TABLE OF CONTENTS

SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1.

Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2.

Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3.

Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4.

Conditions That Affect Weld Bead Shape

8-5.

Gun Movement During Welding

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6.

Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7.

Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8.

Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9.

Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Troubleshooting − Excessive Penetration

8-11. Troubleshooting − Lack Of Penetration

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8-12. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-13. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-14. Troubleshooting − Waviness Of Bead

8-15. Troubleshooting − Distortion

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8-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-17. Troubleshooting Guide For Semiautomatic Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

37

38

38

38

36

36

37

37

32

32

33

34

35

36

39

39

40

40

42

7

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1.

Symbol Usage

.

Indicates special instructions.

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2.

Arc Welding Hazards

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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 grounded equipment is a hazard.

D

Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

D

Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on unit.

D

Additional safety precautions are required when any of the following 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 unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

D

Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D

Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D

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 grounded receptacle outlet.

D

When making input connections, attach proper grounding conductor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.

D

Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

D

Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.

D

Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

D

Do not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power.

D

Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

D

Do not touch hot parts bare handed.

D Allow cooling period before working on gun or torch.

D

To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

OM-232 386 Page 1

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D

Keep your head out of the fumes. Do not breathe the fumes.

D

If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

D

If ventilation is poor, wear an approved air-supplied respirator.

D

Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D

Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or cadmium plated 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.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D

Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching

(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D

Wear approved safety glasses with side shields under your helmet.

D

Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.

D

Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

D

Do not weld where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D

Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

D

Watch for fire, and keep a fire extinguisher nearby.

D

Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

D

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).

D

Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).

D

Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.

OM-232 386 Page 2

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

D

Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

D

Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

D

After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.

D

Use only correct fuses or circuit breakers. Do not oversize or bypass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D

Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

D

Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D

Shut off shielding gas supply when not in use.

D

Always ventilate confined spaces or use approved air-supplied respirator.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

D

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D

Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D

Wear approved ear protection if noise level is high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D

Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.

D

Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

D

Keep cylinders away from any welding or other electrical circuits.

D

Never drape a welding torch over a gas cylinder.

D

Never allow a welding electrode to touch any cylinder.

D

Never weld on a pressurized cylinder − explosion will result.

D

Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D

Keep protective cap in place over valve except when cylinder is in use or connected for use.

D

Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.

D

Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

1-3.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D

Do not install or place unit on, over, or near combustible surfaces.

D

Do not install unit near flammables.

D

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.

D

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

D

Use equipment of adequate capacity to lift and support unit.

D

If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D

Allow cooling period; follow rated duty cycle.

D

Reduce current or reduce duty cycle before starting to weld again.

D

Do not block or filter airflow to unit.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D

Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

D

Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D

Put on grounded wrist strap BEFORE handling boards or parts.

D

Use proper static-proof bags and boxes to store, move, or ship PC boards.

MOVING PARTS can cause injury.

D

Keep away from moving parts.

D

Keep away from pinch points such as drive rolls.

WELDING WIRE can cause injury.

D

Do not press gun trigger until instructed to do so.

D

Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

MOVING PARTS can cause injury.

D

Keep away from moving parts such as fans.

D

Keep all doors, panels, covers, and guards closed and securely in place.

D

Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary.

D

Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

READ INSTRUCTIONS.

D

Read Owner’s Manual before using or servicing unit.

D

Use only genuine replacement parts from the manufacturer.

H.F. RADIATION can cause interference.

D

High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with electronic equipment perform this installation.

D

The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the equipment at once.

D Have the installation regularly checked and maintained.

D 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.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D

Be sure all equipment in the welding area is electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

D

Locate welding operation 100 meters from any sensitive electronic equipment.

D

Be sure this welding machine is installed and grounded according to this manual.

D

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.

OM-232 386 Page 3

1-4.

California Proposition 65 Warnings

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.)

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 reproductive harm. Wash hands after handling.

1-5.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and 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).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:

617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 5060 Mississauga,

1-6.

EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electromagnetic 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 powerfrequency 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.

To reduce magnetic fields in the workplace, use the following procedures:

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:

212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.

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, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for

Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

1.

Keep cables close together by twisting or taping them, or using a cable cover.

2.

Arrange cables to one side and away from the operator.

3.

Do not coil or drape cables around your body.

4.

Keep welding power source and cables as far away from operator as practical.

5.

Connect work clamp to workpiece as close to the weld as possible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recommended.

OM-232 386 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

fre_som_2007−04

7

Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1.

Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures personnelles.

2-2.

Dangers relatifs au soudage à l’arc

.

Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES

CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Sec-

tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.

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 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

Ne pas toucher aux pièces électriques sous tension.

D

Porter des gants isolants et des vêtements de protection secs et sans trous.

D

S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.

D Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.

D

Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D

Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

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 genoux ou couchée ; ou s’il y a un risque

élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante

(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 !

D

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).

D 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 Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D

En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.

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.

D

L’équipement doit être hors tension lorsqu’il n’est pas utilisé.

D

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.

D

Ne pas enrouler les câbles autour du corps.

D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.

D

Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.

D

Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.

D

N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D

Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.

D

S’assurer que tous les panneaux et couvercles sont correctement en place.

D

Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D

Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.

D

Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage.

OM-232 386 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation.

D

Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

D

Ne pas toucher à mains nues les parties chaudes.

D

Prévoir une période de refroidissement avant de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

D

Eloigner votre tête des fumées. Ne pas respirer les fumées.

D

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.

D

Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.

D

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.

D

Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

D

Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D

Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, 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 toxiques en cas de soudage.

LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

D

Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage

(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.

D

Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

D

Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

OM-232 386 Page 6

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peu provoquer leur éclatement. Des étincelles peuven

être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies e des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier e s’assurer que l’endroit ne présente pas de danger.

D

Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.

D

Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.

D

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

D

Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).

D 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.

D

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

D

En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

D

Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

D

Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.

D

Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.

D

Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.

D

Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des blessures dans 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 Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz protecteur en cas de non-utilisation.

D

Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.

LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.

D Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.

D Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D

Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser si elles sont endommagées.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.

D

Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz.

D

Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.

D

Ne jamais souder une bouteille pressurisée − risque d’explosion.

D Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état.

D Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille.

D

Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D

Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.

D

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 sécurité.

2-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO-

SION.

D

Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D

Ne pas installer l’appareil à proximité de produits inflammables.

D

Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D

Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.

D

En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

L’EMPLOI EXCESSIF peut SUR-

CHAUFFER L’ÉQUIPEMENT.

D

Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.

D

Réduire le courant ou le facteur de marche avant de poursuivre le soudage.

D

Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

D

Porter un écran facial pour protéger le visage et les yeux.

D Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

D

Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les circuits imprimés.

D

Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.

D

Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.

DES ORGANES MOBILES peuvent provoquer des blessures.

D

Ne pas s’approcher des organes mobiles.

D Ne pas s’approcher des points de coincement tels que des rouleaux de commande.

OM-232 386 Page 7

LES FILS DE SOUDAGE peuvent provoquer des blessures.

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 engageant le fil de soudage.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer des interférences.

D

Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.

D

Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

D

L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.

DES ORGANES MOBILES peuvent provoquer des blessures.

D

S’abstenir de toucher des organes mobiles tels que des ventilateurs.

D

Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.

D

Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour l’entretien.

D

Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D

Lisez le manuel d’instructions avant l’utilisation ou la maintenance de l’appareil.

D

N’utiliser que les pièces de rechange recommandées par le constructeur.

D

Effectuer régulièrement le contrôle et l’entretien de l’installation.

D

Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.

2-4.

Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de provoquer des interférences.

D

L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

D

Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.

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

Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.

D

Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.

D

En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

Pour les moteurs à essence :

Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.

(Code de santé et de sécurité de Californie, chapitre 25249.5

et suivants)

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 cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation.

Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation.

Pour les moteurs diesel :

Les 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 autres problèmes de procréation.

OM-232 386 Page 8

2-5.

Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

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).

National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, 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, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet : www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

Canadian Standards Association, 5060 Mississauga, Ontario, Canada

2-6.

Information EMF

Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National

Research Council a conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ». Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer les procédures suivantes :

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site

Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :

212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

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, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov).

1.

Garder les câbles ensemble, les torsader, les scotcher, ou les recouvrir d’une housse.

2.

Disposer les câbles d’un côté et à distance de l’opérateur.

3.

Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps.

4.

Garder le poste de soudage et les câbles le plus loin possible de vous.

5.

Connecter la pince sur la pièce aussi près que possible de la soudure.

En ce qui concerne les i

mplants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

OM-232 386 Page 9

OM-232 386 Page 10

.

A complete Parts List is available at www.MillerWelds.com

SECTION 3 − DEFINITIONS

3-1.

Symbols And Definitions

Wire Feed Output

X

Duty Cycle

On

V

Volts

Gas Metal Arc

Welding (GMAW)

Gun

Voltage Input

Increase

Wire Feed Spool

Gun

Press To Reset

U

0

Gas Input

Rated No-Load

Voltage (Average)

SECTION 4 − INSTALLATION

4-1.

Specifications

A. 115 VAC

Rated Welding

Output

Amperage Range

Maximum Open-Circuit Voltage DC

Amperes Input at Rated

Load Output 115 V, 60 Hz,

Single-Phase

KVA

Do Not Switch

While Welding

Off

Gas Output

KW

B. 230 VAC

Rated Welding

Output

150 A @ 23 Volts DC, 40%

Duty Cycle

Amperage Range

30 − 175

Maximum Open-Circuit Voltage DC

32

Amperes Input at Rated

Load Output 230 V, 50/60

Hz, Single-Phase

25.0

C. General Specifications

Wire Type and Diameter

Solid/Stainless

.023 − .035 in

(0.6 − 0.9 mm)

Flux Cored

.030 − .035 in

(0.8 − 0.9 mm)

Aluminum

.030 − .035 in

(0.8 − 0.9 mm)

Wire Feed

Speed

50 − 700 IPM m/min)

Maximum

Spool Size

12 in (305 mm)

Dimensions

H: 30 in (762 mm)

D: 40 in (1016 mm)

KVA

5.74

KW

4.93

Net Weight

Without Gun

158 lb

OM-232 386 Page 11

.

A complete Parts List is available at www.MillerWelds.com

4-2.

Duty Cycle And Overheating

A. 115 VAC

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

NOTICE − Exceeding duty cycle can damage unit or gun and void warranty.

B. 230 VAC

20% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting

Overheating

40% duty cycle at 150 amps

4 Minutes Welding

0

Minutes

15

6 Minutes Resting

OR

A or V

Reduce Duty Cycle duty1 4/95 − 124 655 / 220 896-A

OM-232 386 Page 12

.

A complete Parts List is available at www.MillerWelds.com

4-3.

Volt-Ampere Curves

15

10

5

0

0

35

30

25

20

Range 4

Range 3

Range 2

Range 1

Range 6

Range 5

50 100 150

DC AMPERES

4-4.

Connecting To Weld Output Terminals

200 250

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

.

Ranges 4, 5, and 6 apply to 230

VAC only.

ssb1.1 10/91 − 199 212

1

4

Do not place anything between weld cable terminal and copper bar.

2

3

Tools Needed:

3/4 in (19 mm)

!

Turn off power before connecting to weld output terminals.

!

Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.

Correct Installation

1 Weld Output Terminal

2 Supplied Weld Output Terminal Nut

3 Weld Cable Terminal

4 Copper Bar

Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld

803 778-A

Incorrect Installation output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.

OM-232 386 Page 13

.

A complete Parts List is available at www.MillerWelds.com

4-5.

Installing Work Cable And Clamp

1 Work Cable

2 Boot

Route cable through front panel opening. Slide boot onto work cable.

3 Negative (−) Output Terminal

Connect cable to terminal and cover connection with boot.

Close door.

1

2

3

Tools Needed:

3/4 in

4-6.

Setting Gun Polarity For Wire Type

Changing Polarity

Wire Drive

Assembly Lead

Work Clamp Lead

1

804 909-A

1 Polarity Changeover Label

Information

Always read and follow manufacture’s recommended polarity.

D

D

+

Positive Terminal

-

Negative Terminal

Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW).

Electrode Negative (DCEN): Reverse lead connections at terminals from that shown above for gasless flux core wires

(FCAW). Drive assembly becomes negative.

3/4, 11/16 in

Ref. 190 821-A

OM-232 386 Page 14

.

A complete Parts List is available at www.MillerWelds.com

4-7.

Installing Gas Supply

5

7

4

2

3

Argon Gas Or Mixed Gas

1

2

8 9

CO

2

Gas

3

6

1

Obtain gas cylinders and chain to running gear, wall, or other stationary support so cylinders cannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve.

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection For MIG

Gun

Connect gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source.

7 Gas Flow Adjustment Control

Typical flow rate is 25 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate.

8 CO2 Adapter (Customer

Supplied)

9 O-Ring (Customer Supplied)

Install adapter with O-ring between regulator/flowmeter and CO

2 cylinder.

Rear Panel

Tools Needed:

1-1/8, 5/8 in

Ref. 804 654-A / Ref. 804 898-A

OM-232 386 Page 15

.

A complete Parts List is available at www.MillerWelds.com

4-8.

Installing MIG Wire Spool and Adjusting Hub Tension

Use compression spring with 8 in (200 mm) spools.

When a slight force is needed to turn spool, tension is set.

Installing 1 Or 2 lb Wire Spool

Spindle

Spindle

Install these components onto spindle.

To install either a 1 lb or 2 lb wire spool, follow the procedure as shown in the illustration.

Order extra spring

Part No. 186 437

Remove these components from spindle.

Tools Needed:

15/16 in

072573-B / 802 922

OM-232 386 Page 16

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4-9.

Connecting 1-Phase Input Power For 230 VAC

1

8

L2

5

2

230 VAC, 1

L1

3

4

L1

L2

6

7

1

=GND/PE Earth Ground

!

Installation must meet all National and Local Codes − have only qualified persons make this installation.

!

Disconnect and lockout/tagout input power before connecting input conductors from unit.

!

Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

1 Black And White Input Conductor

(L1 And L2)

2 Green Or Green/Yellow Grounding

Conductor

3 Input Power Cord.

4 Disconnect Device (switch shown in the OFF position)

5 Disconnect Device Grounding

Terminal

6 Disconnect Device Line Terminals

Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

7 Over-Current Protection

Select type and size of over-current

protection using Section 4-10 (fused

disconnect switch shown).

8 Receptacle (NEMA 6-50R)

Customer Supplied

Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:

803 766-B / Ref. 802 443-A

OM-232 386 Page 17

.

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4-10. Electrical Service Guide For 230 VAC

Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.

Input Voltage

Input Amperes At Rated Output

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1 , Time-Delay 2

Normal Operating 3

Min Input Conductor Size In AWG 4

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG 4

60 Hz Single Phase

230

25

30

35

12

79

(24)

12

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

4-11. Extension Cord Data

.

When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.

Input Voltage

Input Power

Phase Hertz Conductor Size Max. Cord Length

115 V

230 V

1

1

60

60

10 AWG

12 AWG

34 ft (10 m)

79 ft (24 m)

OM-232 386 Page 18

.

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4-12. Selecting A Location And Connecting Input Power

!

Do Not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles.

Modifying power cord, connector, and plugs will void product warranty.

18 in (457 mm) of space for airflow

!

Do not move or operate unit where it could tip.

3 4

9

1 5 6

7 8

2

Ref. 804 898-A

!

Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or

CEC Section 20.

For 115 volts ac input power, a 15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. For 230 volts ac input power, see

Section 4-9.

1 Rating Label

Supply correct input power.

2 Power Cord Connector

3 Plug − NEMA Type 5-15P

4 Receptacle − NEMA Type 5-15R

(Customer Supplied)

5 Plug − NEMA Type 5-20P (Optional)

6 Receptacle NEMA Type 5-20R

(Customer Supplied)

7 Plug − NEMA Type 6-50P

8 Receptacle − NEMA Type 6-50R

(Customer Supplied)

Select plug for power supply receptacle available at site. Install plug onto power cord adapter. As threaded collar is tightened, push plug onto adapter until collar is completely tight.

Connect plug to receptacle.

9 Cylinder Support Bracket

Holes in the bracket provide a location to store the unused power cord plugs.

OM-232 386 Page 19

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4-13. Threading Welding Wire

4

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Outlet Wire Guide

7 Gun Conduit Cable

Lay gun cable out straight.

1 2

3

5

6

.

Hold wire tightly to keep it from unraveling.

6 in

(150 mm)

7

Tools Needed:

Open pressure assembly.

Tighten

1

2

3

4

Pull and hold wire; cut off end.

.

Use pressure indicator scale to set a desired drive roll pressure.

Pressure

Indicator

Scale

Push wire thru guides into gun; continue to hold wire.

Close and tighten pressure assembly, and let go of wire.

Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle

OM-232 386 Page 20

Remove gun nozzle and contact tip.

Tighten

3

4

1

2

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Turn On.

Cut off wire. Close and latch door.

Ref. 804 897-A

.

A complete Parts List is available at www.MillerWelds.com

4-14. Installing Optional Gas Valve, Receptacle, And Barbed Fitting For Optional Spool

Gun

1

3

6

7

2

4

5

6

8

2

804 990-A

Tools Needed:

1/4 in

9/16 in

!

Turn Off unit, and disconnect input power.

Remove wrapper.

1 Rear Panel

2 Snap-in Blank Location

3 Center Baffle Barbed Fitting Hole

Location

4 Front Panel

5 Center Baffle Ground Clip

6 Circuit Board PC1

7 Receptacle RC1

8 Receptacle RC2

Remove snap-in blank from rear panel, and install supplied gas valve.

Connect plug from gas valve wiring harness into receptacle RC1.

Install supplied barbed fitting into center baffle hole. Connect gas hose between gas valve and barbed fitting. Secure with hose clamps.

Remove snap-in blank from front panel, and Install supplied 4-position receptacle.

Connect plug from 4-position receptacle wiring harness into receptacle RC2.

Connect capacitors to center baffle ground clip.

Reinstall wrapper.

OM-232 386 Page 21

.

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4-15. Connecting An Optional Spool Gun

4

3

1

2

1 Barbed Fitting

.

If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose.

Connect spool gun gas hose to barbed fitting.

2 Gun Trigger Plug

Insert plug into receptacle with spool gun symbol, and tighten threaded collar.

3 Negative (−) Output Terminal

4 Positive (+) Output Terminal

Connect weld cable from spool gun to positive output terminal.

Close door.

804 922-A

OM-232 386 Page 22

5-1.

Controls

.

A complete Parts List is available at www.MillerWelds.com

SECTION 5 − OPERATION

2

3

1

Ref. 226 649-C

1 Voltage Control

Set Voltage control according to the parameter chart for good starting point.

Turn control clockwise to increase voltage.

2 Wire Speed Control

Set Wire Speed control according to the parameter chart. Increase or decrease wire speed to obtain desired bead profile and travel speed.

3 Over Temp Light

If unit overheats, light turns on and output stops. Allow unit to cool before resuming operation.

OM-232 386 Page 23

.

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5-2.

Weld Parameter Chart

OM-232 386 Page 24

*Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust voltage and wire feed speed to optimize your settings.

Input Line

Voltage*

Higher e.g. 240

Volts AC

230 Volts AC

Parameter

Chart Settings

Weld Will Be

Hotter

Lower Settings

Use Parameter

Chart

Lower e.g. 218

Volts AC

Weld Will Be

Colder

Raise Settings

.

A complete Parts List is available at www.MillerWelds.com

226 652-A

OM-232 386 Page 25

.

A complete Parts List is available at www.MillerWelds.com

SECTION 6 − MAINTENANCE &TROUBLESHOOTING

6-1.

Routine Maintenance

!

Disconnect power before maintaining.

l

= Replace n

= Check

Z

= Change

~

= Clean

* To be done by Factory Authorized Service Agent

Every

3

Months

Every

6

Months l

Unreadable Labels

OR

~

Weld Terminals nl

Weld Cables

.

Maintain more often during severe conditions.

Reference

~

Inside Unit n

Apply Light Coat Of Oil

Or Grease To Drive Motor

Shaft

6-2.

Unit Overload

Thermostats TP1 in rectifier SR1 and TP2 in stabilizer Z1 protect the unit from damage due to overheating. If TP1 and/or TP2 opens welding output will shut off, and the Over Temp light will turn on. Wait until Over Temp light turns off before trying to weld.

6-3.

Changing Drive Roll and Wire Inlet Guide

2

1

4

1 Securing Screw

2 Inlet Wire Guide

Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw.

3 Drive Roll

The drive roll consists of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to

thread (see Section 4-13).

4 Drive Roll Securing Nut

Turn nut one click to secure drive roll.

3

Tools Needed:

7/16 in

Ref. 804 914-A

OM-232 386 Page 26

.

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6-4.

Aligning Drive Rolls and Wire Guide

1

2

3

Correct

4

5

Incorrect

!

Turn Off power.

View is from top of drive rolls looking down with pressure assembly open.

1 Drive Roll Securing Nut

2 Drive Roll

3 Wire Guide

4 Welding Wire

5 Drive Gear

Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.

Close pressure roll assembly.

Tools Needed:

6-5.

Troubleshooting

Ref. 800 412-A

Welding Trouble

No weld output; wire does not feed.

No weld output; wire feeds.

Low weld output.

Low, high, or erratic wire speed.

Over temperature light on.

Over temperature light blinks rapidly.

Over temperature light blinks slowly.

Remedy

Secure power cord plug in receptacle (see Section 4-12).

Check power switch/supplementary protector, and reset if necessary. If supplementary protector is not tripped, replace power switch.

Replace building line fuse or reset circuit breaker if open (see Section 4-12).

Thermostat TP1 or TP2 open (overheating). Allow fan to run; the thermostat will close when the unit has

cooled (see Section 6-2).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section welding gun Owner’s Manual).

Connect unit to proper input voltage or check for low line voltage (see Section 4-12).

Readjust front panel settings (see Section ).

Change to correct size drive roll (see Section 6-3).

Readjust drive roll pressure (see Section 4-13).

Unit has overheated and output stops. Let unit cool before continuing welding operation.

Gun trigger is closed or shorted when unit power is turned on.

Indicates a malfunction in the wire drive system or drive motor overcurrent. Check for proper spool brake adjustment or obstructions in the wire feed system. Check wire guides, gun liner and contact tip.

OM-232 386 Page 27

.

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Wire Drive/Gun Trouble Remedy

Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see welding gun Owner’s Manual).

Adjust drive roll pressure (see Section 4-13).

Readjust hub tension (see Section 4-8).

Replace contact tip if blocked (see welding gun Owner’s Manual).

Clean or replace wire inlet guide or liner if dirty or plugged (see welding gun Owner’s Manual).

Replace drive roll if worn or slipping (see Section 6-3).

Check and clear any restrictions at drive assembly (see Section 6-3).

Have nearest Factory Authorized Service Agent check drive motor.

OM-232 386 Page 28

Notes

OM-232 386 Page 29

SECTION 7 − ELECTRICAL DIAGRAM

OM-232 386 Page 30

Figure 7-1. Welding Power Source Circuit Diagram

229 598-B

OM-232 386 Page 31

SECTION 8 − MIG WELDING (GMAW) GUIDELINES

8-1.

Typical MIG Process Connections

!

Weld current can damage electronic parts in vehicles.

Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

Regulator/

Flowmeter

Wire Feeder/

Power Source

Shielding Gas

Gas

Gun

Work Clamp

Workpiece mig1_2007−05 / Ref. 801 909-A

OM-232 386 Page 32

8-2.

Typical MIG Process Control Settings

.

These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

Material thickness determines weld parameters.

1/8 or 0.125 in Convert Material

Thickness to

Amperage (A)

(0.001 in = 1 ampere)

0.125 in = 125 A

.035 in

Wire Size

0.023 in

0.030 in

0.035 in

Amperage Range

30 − 90 A

40 − 145 A

50 − 180 A

Select Wire Size

Wire

Size

0.023 in

0.030 in

0.035 in

Recommendation

3.5 in per ampere

2 in per ampere

1.6 in per ampere

Wire Speed

(Approx.)

3.5 x 125 A = 437 ipm

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

Select Wire Speed

(Amperage)

125 A based on 1/8 in material thickness ipm = inches per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Voltage controls height and width of weld bead.

Select Voltage

Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)

OM-232 386 Page 33

8-3.

Holding And Positioning Welding Gun

.

Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.

1

2

3

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

5

4

0

°

-15

°

90

°

90

°

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

45

°

0

°

-15

°

45

°

End View of Work Angle Side View of Gun Angle

FILLET WELDS

S-0421-A

OM-232 386 Page 34

8-4.

Conditions That Affect Weld Bead Shape

.

Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed

(weld current), and voltage.

10

°

Push

10

°

Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal

ELECTRODE EXTENSIONS (STICKOUT)

Long

Short Normal Long

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow Normal

GUN TRAVEL SPEED

Fast

S-0634

OM-232 386 Page 35

8-5.

Gun Movement During Welding

.

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better.

1 2

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam

3 Weave Patterns

Use weave patterns to cover a wide area in one pass of the electrode.

3

8-6.

Poor Weld Bead Characteristics

1

S-0054-A

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

2 3 4

5

8-7.

Good Weld Bead Characteristics

1

S-0053-A

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater During

Welding

Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals being welded.

4 No Overlap

5 Good Penetration into Base

Metal

2 3 4

5

S-0052-B

OM-232 386 Page 36

8-8.

Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes

Wire feed speed too high.

Voltage too high.

Electrode extension (stickout) too long.

Workpiece dirty.

Insufficient shielding gas at welding arc.

Dirty welding wire.

Incorrect polarity.

S-0636

Corrective Actions

Select lower wire feed speed.

Select lower voltage range.

Use shorter electrode extension (stickout).

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Check polarity required by welding wire, and change to correct polarity at welding power source.

8-9.

Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets in weld metal.

S-0635

Insufficient shielding gas at welding arc.

Wrong gas.

Possible Causes

Dirty welding wire.

Corrective Actions

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Use welding grade shielding gas; change to different gas.

Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

8-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Excessive Penetration Good Penetration

Possible Causes

Excessive heat input.

Corrective Actions

Select lower voltage range and reduce wire feed speed.

Increase travel speed.

S-0639

OM-232 386 Page 37

8-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes

Improper joint preparation.

Improper weld technique.

Insufficient heat input.

Incorrect polarity.

S-0638

Corrective Actions

Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

Check polarity required by welding wire, and change to correct polarity at welding power source.

8-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes

Workpiece dirty.

Insufficient heat input.

Improper welding technique.

S-0637

Corrective Actions

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Select higher voltage range and/or adjust wire feed speed.

Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

8-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

S-0640

Possible Causes

Excessive heat input.

OM-232 386 Page 38

Corrective Actions

Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

8-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

S-0641

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand.

Support hand on solid surface or use two hands.

8-15. Troubleshooting − Distortion

Possible Causes

Excessive heat input.

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves in the direction of the weld bead.

Corrective Actions

Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

S-0642

OM-232 386 Page 39

8-16. Common MIG Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.

Gas

Spray Arc Steel

Application

Short Circuiting Steel

Short Circuiting

Stainless Steel

Aluminum

X

Argon

Argon + 25% CO

2

80% or greater Argon + balance CO

2

or Oxygen

100% CO

2

Tri-Mix2

1 Limited short circuiting use

2 90% HE + 7-1/2% AR + 2-1/2% CO

2

X

X

X

X

1

X

8-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause

Wire feed motor operates, but Too little pressure on wire feed rolls.

Incorrect wire feed rolls.

Remedy

Increase pressure setting on wire feed rolls.

Check size stamped on wire feed rolls, replace to match wire size and type if necessary.

Wire curling up in front of the

Wire spool brake pressure too high.

Restriction in the gun and/or assembly.

Too much pressure on wire feed rolls.

Incorrect cable liner or gun contact tip size.

Decrease brake pressure on wire spool.

Check and replace cable, gun, and contact tip if damaged. Check size of contact tip and cable liner, replace if necessary.

Decrease pressure setting on wire feed rolls.

Check size of contact tip and check cable liner length and diameter, replace if necessary.

Gun end not inserted into drive housing properly.

Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls.

Replace liner.

Dirty or damaged (kinked) liner.

Wire feeds, but no gas flows.

Gas cylinder empty.

Gas nozzle plugged.

Replace empty gas cylinder.

Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted.

Open gas valve at cylinder and adjust flow rate.

Restriction in gas line.

Check gas hose between flowmeter and wire feeder, and gas hose in gun and cable assembly.

Have Factory Authorized Service Agent repair wiring.

Loose or broken wires to gas solenoid.

Gas solenoid valve not operating.

Have Factory Authorized Service Agent replace gas solenoid valve.

Incorrect primary voltage connected to welding power source.

Check primary voltage and relink welding power source for correct voltage.

OM-232 386 Page 40

Problem

Welding arc not stable.

Probable Cause

Wire slipping in drive rolls.

Remedy

Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary.

Wrong size gun liner or contact tip.

Match liner and contact tip to wire size and type.

Incorrect voltage setting for selected wire feed speed on welding power source.

Readjust welding parameters.

Loose connections at the gun weld cable or work cable.

Check and tighten all connections.

Gun in poor shape or loose connection inside gun.

Repair or replace gun as necessary.

OM-232 386 Page 41

SECTION 9 − PARTS LIST

9-1.

Drive Roll And Wire Guide Kits

.

Base selection of drive rolls upon the following recommended usages:

1 V-Grooved rolls for hard wire.

2 U-Grooved rolls for soft and soft shelled cored wires.

3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).

4 V-Knurled rolls for hard shelled cored wires.

5 Drive roll types may be mixed to suit particular requirements (e.g. V-Knurled roll in combination with U-Grooved).

Fraction

.023/.025 in.

.030/.035 in.

.030 in.

.035 in.

Wire Diameter

Decimal

.023/.025 in.

.030/.035 in.

.030 in.

.035 in.

Metric

0.6 mm

0.8/0.9 mm

0.8 mm

0.9 mm

.

A complete Parts List is available at www.MillerWelds.com

087 131

204 579

079 594

079 595

Part No.

Drive Roll

Type

087 130

203 526

053 695

053 700

V-Grooved

V-Grooved

V-Grooved

V-Grooved

056 192

056 192

056 192

056 192

OM-232 368 Page 42

Warranty Questions?

Call

1-800-4-A-MILLER for your local

Miller distributor.

Your distributor also gives you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

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.

Effective January 1, 2008

(Equipment with a serial number preface of LJ or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.

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.

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.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.

* Canvas Covers

Miller’s True Blue

®

Limited Warranty shall not apply to:

1.

2.

*

*

*

*

*

Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

APT & SAF Model Plasma Cutting Torches

Remote Controls

Accessory (Kits)

Replacement Parts (No labor)

* Spoolmate Spoolguns

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.)

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.

1.

5 Years Parts — 3 Years Labor

* Original main power rectifiers only to include SCRs, diodes, and discrete rectifier modules

2.

3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Process Controllers

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.

*

*

Semi-Automatic and Automatic Wire Feeders

Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

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.

3.

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

*

*

Spoolguns)

Positioners and Controllers

Automatic Motion Devices

* RFCS Foot Controls

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.

*

*

*

Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

Water Coolant Systems (Non-Integrated)

Flowgauge and Flowmeter Regulators (No Labor)

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.

* HF Units

* Grids

*

*

*

*

*

Spot Welders

Load Banks

Arc Stud Power Sources & Arc Stud Guns

Racks

Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

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,

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.

* Field Options

(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)

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.

4.

5.

* Subarc Wire Drive Assemblies

6 Months — Batteries

90 Days — Parts

* MIG Guns and Subarc (SAW) Guns

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, but may vary from province to province.

miller_warr 2008-01

Owner’s Record

Please complete and retain with your personal records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Contact the Delivering Carrier to:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information and Parts)

Circuit Diagrams

Welding Process Handbooks

To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s

Transportation Department.

PRINTED IN USA

©

2008 Miller Electric Mfg. Co. 2008−01

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066 www.MillerWelds.com