Miller Electric Axcess 300 Owner`s manual

OM-231 185N
2011−01
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
™
Auto-Axcess 300
CE
Visit our website at
www.MillerWelds.com/ams
File: Advanced Manufacturing Systems
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
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 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
3-2. WEEE Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
5-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
5-5. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
5-7. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
5-9. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Weld Output Terminals And Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
5-11. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
22
5-14. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
24
5-16. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
25
6-2. Front Panel Controls (See Section 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Front Panel Controls - Continued (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
28
6-4. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Robot Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Robot Auto-Calibration Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
30
31
6-7. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
TABLE OF CONTENTS
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Process Control Module PC4 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Diagnostic LEDs On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Diagnostic LEDs On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8. User Interface Module PC7 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9. Diagnostic LEDs On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-10. Automation Interface Module PC9 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-11. Diagnostic LEDs On Automation Interface Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-12. Network And Module Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
34
34
34
35
35
35
36
36
37
37
38
41
42
42
43
43
44
44
45
46
47
48
49
56
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
907349
Product
Auto­Axcess 300 CE Autoline
Council Directives:
• 2006/95/EC Low Voltage
• 2004/108/EC Electromagnetic Compatibility
Standards:
• IEC 60974­1: 2005 Arc Welding Equipment – Welding Power Sources
• IEC 60974­10: 2007 Arc Welding Equipment Electromagnetic Compatibility Requirements
• EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0 Hz – 300Hz) BS EN 50445:2008.
Signatory:
November 23, 2010
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
241986‐E
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2010−03
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates 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.
. Indicates special instructions.
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.
1-2. Arc Welding 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
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
OM-231 185 Page 1
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 from arc rays and
sparks 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.
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.
OM-231 185 Page 2
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.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect ImplantedMedical 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 EQUIPMENT can injure.
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.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
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 and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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 injure.
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.
D
D
D
D
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.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
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.
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.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
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.
D
D
D
D
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.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
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-231 185 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.
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.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
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).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, 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, Quincy, MA 02269 (phone: 1-800-344-3555, 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).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (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,
Quincy, MA 02269 (phone: 1-800-344-3555, 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 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-231 185 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
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.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2010−03
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.
. 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.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
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 UNIQUEMENT 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,
D
D
D
D
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
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-231 185 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
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.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
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.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et 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 et 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.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
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 Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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 Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
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 intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
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 pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (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-231 185 Page 6
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 porteélectrode 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
SALETES 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 ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester
à distance.
D Les porteurs d’implants médicaux doivent consulter
leur médecin et le fabricant du dispositif avant de s’approcher
de la zone où se déroule du soudage à l’arc, du soudage
par points, du gougeage, de la découpe plasma
ou une opération de chauffage par induction.
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.
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.
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’EXPLOSION.
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’ÉQUIPEMENT peut
provoquer des blessures.
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.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER 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 PROJETÉES
peuvent 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 ÉLECTROSTATIQUES 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.
OM-231 185 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
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.
Les PIÈCES MOBILES peuvent
causer 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 Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
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 Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
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.
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
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.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures 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.
2-4. Proposition californienne 65 Avertissements
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.
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
OM-231 185 Page 8
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
Pour les moteurs à essence :
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.
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).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, 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, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.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).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (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).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
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-231 185 Page 9
OM-231 185 Page 10
SECTION 3 − DEFINITIONS
3-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
2.1
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
Protect yourself from electric shock
by insulating yourself from work and
ground.
Disconnect input plug or power
before working on machine.
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
4
2.3 Use ventilating fan to remove fumes.
4.1 Wear hat and safety glasses. Use
ear protection and button shirt collar.
Use welding helmet with correct
shade of filter. Wear complete body
protection.
3
Welding sparks can cause explosion
or fire.
3.1 Keep flammables away from welding.
Do not weld near flammables.
Arc rays can burn eyes and injure
skin.
3.2 Welding sparks can cause fires.
Have a fire extinguisher nearby, and
have a watchperson ready to use it.
5
Become trained and read the
instructions before working on the
machine or welding.
3.3 Do not weld on drums or any closed
containers.
6
Do not remove or paint over (cover)
the label.
1/09
OM-231 185 Page 11
2
3
4
5
1
6
V
V
> 5 min
V
219844-A
7
8
9
10
4/04
1
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
2
Electric shock from wiring can kill.
3
Disconnect input plug or power
before working on machine.
4
Hazardous voltage remains on input
capacitors after power is turned off.
Do not touch fully charged
capacitors.
5
Always wait 5 minutes after power is
turned off before working on unit, OR
6
Check input capacitor voltage, and
be sure it is near 0 before touching
any parts.
7
When power is applied failed parts
1
can explode or cause other parts to
explode.
8 Flying pieces of parts can cause
injury. Always wear a face shield
when servicing unit.
9 Always wear long sleeves and button
your collar when servicing unit.
10 After taking proper precautions as
shown, connect power to unit.
1
2
3
∠ = <60 °
∠
4
5
S-179 309-A
2
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both eye bolts. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one eye bolt to lift
or support unit.
5
1/96
3-2. WEEE Label
Do not discard this product with
general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
OM-231 185 Page 12
3-3. Symbols And Definitions
A
Direct Current
(DC)
Alternating
Current (AC)
Output
Circuit Breaker
Remote
On
Off
Positive
Negative
Voltage Input
Arc Force
Constant Voltage
Inductance
Protective Earth
(Ground)
Line Connection
Gas Metal Arc
Welding (GMAW)
Three Phase Static
Frequency ConverterTransformerRectifier
Increase
U0
Rated No Load
Voltage (Average)
Hz
Hertz
U1
IP
Primary Voltage
Degree Of
Protection
U2
I2
Pulsed
I1max
V
Amperage
Rated Maximum
Supply Current
Conventional
Load Voltage
Rated Welding
Current
Single Phase
I1eff
Maximum Effective
Supply Current
S
X
%
Voltage
Duty Cycle
Percent
Three Phase
Suitable for Some
Hazardous
Locations
OM-231 185 Page 13
SECTION 4 − SPECIFICATIONS
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
This equipment complies with IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 4,371,835 at the interface
point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 4,371,835.
ce-emc 1 2010-10
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-231 185 Page 14
SECTION 5 − INSTALLATION
. Appearance of actual unit may vary from unit shown in manual.
5-1. Specifications
Input
Power
Rated
Welding
Output
Three
Phase
225 A @
25 V DC,
100%
Duty
Cycle
Wire Feed
Speed
Range**
Voltage
Range
Standard:
50-1400
ipm
(1.3-35.6 mpm)
10-44
Wire
Diameter
Range
Amperes Input At Rated
Load Output
60 Hz,
Three-Phase
Max
Open
Circuit Voltage
DC
Input
KW
7.2
(0.2*)
6.9
(0.04*)
400V
10.4
.030-.062 in.
(0.8-1.6 mm)
Input
kVA
80
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.
5-2. Dimensions And Weight
Hole Layout Dimensions
A
A
17-3/32 in. (434
mm)
B
17-3/8 in. (441 mm)
C
19-3/32 in. (485 mm)
D
16-3/32 in. (409 mm)
E
1/2 in. (13 mm)
22-1/2 in.
(572 mm)
C
23 in.
(584 mm)
B
17-3/32 in.
(434 mm)
Weight
112 lb (51 kg) Net
134 lb (61 kg) Ship
E
D
Ref. 803 675-A
OM-231 185 Page 15
5-3. Duty Cycle And Overheating
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 and void warranty.
100% Duty Cycle At 225 Amperes
60% Duty Cycle At 300 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 230 226-B
5-4. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
CV MODE
80
70
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
VOLTAGE
60
50
40
30
20
10
0
0
100
200
300
AMPERAGE
400
500
600
va_curve1 4/95
5-5. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
OM-231 185 Page 16
5-6. Selecting A Location
Movement
!
Tipping
Do not move or operate
unit where it could tip.
2
OR
1
Location
!
Special installation may be required where gasoline or volatile
liquids are present − see NEC Article 511 or CEC Section 20.
!
Do not stack units. Beware of
tipping.
1
Lifting Forks
Use lifting forks to move unit.
3
Extend forks beyond opposite side
of unit.
2
Hand Cart
Use cart or similar device to move
unit.
3
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
18 in.
(460 mm)
loc_2 3/96 -Ref. 803 675-A
5-7. Connection Diagram
. The proper interface kit must
2
be installed in the welding
power source/interface unit to
allow it to be connected to the
robot.
5
3
1
4
1
6
7
12
10
8
Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 Robot Input/Output Cable
7 Gas And Motor Control Cable
8 Welding Power
Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
11 Voltage Sensing Lead
Recommended for Accu-pulse and
RMD (optional).
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
12 Positive (+) Weld Cable
11
9
Ref. 803 675-A / Ref. 801 915-A
OM-231 185 Page 17
5-8. Rear Panel Receptacles And Supplementary Protectors
1
4
5
6
1
115 V 10 A AC Receptacle RC2
Receptacle
supplies
60
Hz
single-phase power. Maximum output
from RC2 is limited by supplementary
protector CB1 to 10 amps.
2
3
Supplementary Protector CB1
Supplementary Protector CB2
CB1 protects 115 volt receptacle RC2
from overload. If CB1 opens, RC2 does
not work.
2
3
CB2 protects the wirefeed motor from
overload. If CB2 opens, the wirefeeder
does not work.
. Press
button to reset breaker. If
breaker continue to open, contact a
Factory Authorized Service Agent.
4
Wirefeed/Gas Receptacle RC8
Use receptacle to connect gas and
motor control cable to power source
(see Sections 5-7 and 10 for additional
information).
5
Peripheral Receptacle RC25
Receptacle provides connection to
touch sensor, water flow switch, jog +/−,
and n/o relay contacts circuitry (see
Section 5-11).
6
Robot Interface Receptacle RC72
Use receptacle to connect robot input/
output cable (see Sections 5-7 and 10
for additional information).
Ref. 803 676-A
OM-231 185 Page 18
5-9. Connecting To Weld Terminals
. If using an electrode negative (straight polarity)
process, the volt sense lead must be connected
to the work.
1
2
3
6
Do not place
anything between
weld cable terminal
and copper bar.
4
Tools Needed:
5
3/4 in. (19 mm)
Correct Installation
Incorrect Installation
Ref. 803 675-A / 803 778-A
!
!
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.
Determine total cable length in weld circuit
(both positive and negative cables
combined) and maximum welding
amperes. See Section 5-10 to select proper
cable size.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
Connect positive weld cable to Positive (+)
weld terminal and negative (−) cable to
Negative weld terminal.
3
Weld Output Terminal
4
Supplied Weld Output Terminal Nut
5
Weld Cable Terminal
6
Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld 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-231 185 Page 19
5-10. Weld Output Terminals And Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft
(30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
Weld Cable Size*** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding****
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
100 ft (30 m) or Less
Welding
Amperes**
Positive
)
* This
150 ft
(45 m)
200 ft
(60 m)
10 − 60%
60 − 100%
Duty Cycle Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
Negative
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
Ref. 803 677-A
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
700
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
800
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
4 ea. 4/0
(4x120)
4 ea. 4/0
(4x120)
*
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.
***Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
****For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 2009−08
. In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding
characteristics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and
4/0 for 450 ampere welding power sources when total cable length is less than 100 ft (30m).
OM-231 185 Page 20
5-11. Peripheral Receptacle Functions
Function
C B
D
L
E
F
M
J
H
Not used.
B
Not used.
C*
Circuit common.
D
Contact closure to C completes 24 volts DC solenoid
circuit to purge shielding gas line.
E
Contact closure to F indicates coolant flow switch is
closed and recirculating coolant system is
operational.
F*
Circuit common.
Jog
H**
Contact closure to circuit common advances welding
wire at wire drive assembly.
Retract
J**
Contact closure to circuit common retracts welding
wire at wire drive assembly.
K
Contact closure to L energizes Touch Sensor
circuitry.
L*
Circuit common.
M
Part touched +24 volts DC output signal referenced
to circuit common.
Purge
Coolant Flow
Switch Input Signal
Ref. 803 675-A
Socket Information
A
A
K
Socket
Touch Sensor ON
And Output Signal
*Circuit common is same electrical reference point.
**Speed of Jog + (advance) and Jog − (retract) is 60 ipm for 3 seconds, then it automatically changes to 700 ipm.
Note: A customer supplied matching amphenol plug, factory Part No. 194 847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief
clamp 97-3057-12(0621)] is required to use peripheral receptacle.
5-12. Motor Control Receptacle Functions
Socket
G
J
K
Socket Information
C
A
F
E
H
D
B
Ref. 803 675-A
A
Not used.
B
Motor negative (−).
C
Tach A.
D
Motor positive (+).
E
Tach common.
F
Gas valve.
G
Electrode sense.
H
Tach +5 volts DC.
J
Tach B.
K
Gas valve.
OM-231 185 Page 21
5-13. Electrical Service Guide
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
50/60 Hz
Three
Phase
Input Voltage (V)
400
Input Amperes (A) At Rated Output
10.4
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
10
3
15
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
14
223
(68)
14
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps 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.
OM-231 185 Page 22
5-14. Connecting Input Power
3
= GND/PE Earth Ground
5
8
2
3
L1
4
L2
7
6
L3
1
Route input conductors
to filter board.
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Route ground conductor
through tubing and current transducer to
ground terminal.
lk glk lk
ks;dg ks;d ks;dg ;dglk
s;ldfg ks;ldfg s;ldfg ;ldfgks
ds;lgk ds;lgslgkds;lgkldgksdlks
Aslgk ldhfsgk A
s
;ldkg
As
S
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
219842-A
Tools Needed:
804 750-A / Ref. 803 855-A / Ref. 803 766-A / 219 842-A
5/16 in.
!
!
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 9-3 before
proceeding.
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.
!
Make input power connections to the
welding power source first.
!
Always
connect
green
or
green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.
. The
Auto-Line circuitry in this unit
automatically links the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be
connected to any input power between 208
and 575 VAC without relinking the power
source.
1
Input Power Conductors (Customer
Supplied Cord)
Reinstall side panel onto welding power
source.
Select size and length of conductors using
Section 5-13. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Disconnect
Device
Connections
3
Disconnect Device (switch shown in
the OFF position)
Welding Power Source Input Power
Connections
4
Green Or Green/Yellow Grounding
Conductor
2
5
Disconnect Device Grounding Terminal
6
Input Conductors (L1, L2 And L3)
7
Disconnect Device Line Terminals
Strain Relief
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief and tighten screws.
Input
Power
S Use large strain relief for input conductor
size 8 and larger.
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
S Use small strain relief with reducing
washers for input conductor size 10.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
Connect input conductors as shown in
illustration.
8
Route green or green/yellow grounding
conductor through current transducer and
connect to welding power source grounding
terminal first. Then connect input conductors
L1, L2, and L3 to welding power source line
terminals.
Over-Current Protection
Select type and size of over-current protection using Section 5-13 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
OM-231 185 Page 23
5-15. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.
The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral
receptacle. Turning on touch sensor causes a DC voltage to be present on the welding wire. When welding wire
touches the weldment, the voltage sensing circuit closes, and a +24 volts DC output signal is sent to the robot control
indicating weldment detection. Touch sensor DC voltage on the welding wire is 80 volts DC. As soon as touch sensor
turns on, WIRE LIVE appears on the front panel display.
5-16. Remote Program Select
. Remote Program Select is factory set to “On”. WaveWriter software is required to turn this function “Off”.
When Remote Program Select is On, a remote device or robot pendant may be used to select programs. When Off,
program selection must be done from the robot pendant.
5-17. Remote Program Setting
. When Remote Program Select is “On”, program selection will be determined by remote input once a weld is initiated. Prior to welding, program
selection can be done in a normal manner from the welding power source front control panel.
See the following table for the remote program select binary code.
Program No.
Output A
Output B
Output C
1
Off
Off
Off
2
On
Off
Off
3
Off
On
Off
4
On
On
Off
5
Off
Off
On
6
On
Off
On
7
Off
On
On
8
On
On
On
OM-231 185 Page 24
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Synergic
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse
settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed
speed setting.
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual
arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in MIG
programs.
Program
Eight active slots for selection of various processes, wire types, and parameters.
Process
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
MIG
CV weld process with individual settings of voltage and wire speed.
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory
taught data. Adaptive method is controlled by frequency adjustment.
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.
Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths, better
puddle control, more tolerant of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in
at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps.
Accuspeed (optional)
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed to be
tight and fast. Front panel display is ACCU − SPED.
AccuCurve
CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has
a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
RMD (optional)
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of RMD are well
suited to thin materials, improves gap filling and spatter reduction. Provides less heat input into workpiece,
minimizes distortion and allows use of larger diameter wire on thin gauge materials.
Wire Type
Selection of wire type by alloys and classification.
Gas Type
Selection of shielding gas being used in application.
Process Set Up
Selection procedure for entering program.
Program Load
Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.
Time
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in the Arc On
and Analog input or the Arc On and No Analog input modes).
Arc Length
Distance from end of wire electrode to workpiece.
WFS
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In
pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire electrode
(one knob control).
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control
Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD
(optional).
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per
second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes
the welding puddle more fluid.
Sharp Arc
In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory
pulse data. In RMD (optional) this control will affect the arc in much the same way as inductance.
Adjust
Control knob used to change or set parameters and functions.
Sequence
Selecting Sequence will allow setting of preflow, start, crater, postflow, and retract times and parameters (only
available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes).
Preflow
Setting a time value for gas flow prior to arc start (only available on Auto Axcess models in the Arc On and
Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File
Management software).
OM-231 185 Page 25
6-1 . Operational Terms (Continued)
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (only available on Auto Axcess
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software).
Weld
Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software].
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (only available on Auto Axcess
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software).
Postflow
Setting a time value for gas flow after arc end (only available on Auto Axcess models in the Arc On and Analog
input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File Management software).
Retract
Sequence function that allows the wire to move back towards the contact tip when a welding operation is
completed. Setting is both speed (IPM) and time (sec), (only available on Auto Axcess models in the Arc On
and Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File
Management software).
Auto Thread
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will
automatically feed wire. Default setting is 72 inches at a feed rate of 700 ipm. Pressing jog, purge, or trigger
switch will terminate the auto-threading feature. These values can be changed using a PDA with File
Management/WaveWriter software.
OM-231 185 Page 26
6-2. Front Panel Controls (See Section 6-3)
15
14
13
1
4
12
V
A
A
3
11
10
8
5
9
6
7
16
Adjust
Setup
Arc Control
2
. When an LED is lit, it means the related function is active.
219 712-A
1 Program Display
Displays the number of the active program.
2 Adjust Knob
Turn the Adjust knob to change program
number, Setup, Arc Control, and weld
parameters.
3 Program Push Button LED
The LED lights when the Program Push
Button is active.
4 Program Push Button
Press push button (LED lights) and turn Adjust
knob to select active program.
The letter C is displayed with the program
number if the program has been changed from
the factory settings using the optional PDA
with File Management/WaveWriter software
(see File Management/WaveWriter Owner’s
Manual).
. The program cannot be changed through
the front panel while welding.
Press and hold button to see program name.
Custom programs are named using optional
PDA with File Management/WaveWriter
software. Program name is shown in upper
and lower displays (items 13 and 15).
5
Setup Mode Indicators
Gas Type LED
When this LED is lit, turn the Adjust knob to
select the desired weld gas. Gas type choices
vary according to the selected weld process.
The lit LED indicates which setup mode is
active. Setup mode parameters are shown in
Display Windows (see Items 13 and 15).
See Table 5-1 for all gas abbreviations.
Process LED
The LED lights to indicate one of the setup
modes is active.
When this LED is lit, turn the Adjust knob to
select the desired weld process. Choices
include pulse welding (displayed as PULS),
Accu-pulse, MIG welding (MIG), and Accu
Puls/RMD [Regulated Metal Deposition
(optional)].
Wire Type LED
When this LED is lit, turn the Adjust knob to
select the desired wire type, wire alloy, and
size. Wire type and size choices vary
according to the selected weld process.
Choices may include steel (displayed as
STL), stainless steel (SS), metal core
(MCOR), aluminum (ALUM). See Table 5-1
for all wire abbreviations.
6
7
Setup Push Button LED
Setup Push Button
Press button to select Process, Wire Type,
Wire Diameter, or Gas Type parameters.
. In order for selections to be retained in
memory, the Setup push button must be
pressed six times before any other push
button is pressed: once to select Process,
again to select Wire Type, again to select
Wire Alloy, again to select Wire Size,
again to select Gas Type, and a sixth time
to store selections in memory. The
displays will temporarily show “PROG
LOAD” to indicate the data is being stored
in memory.
OM-231 185 Page 27
6-3. Front Panel Controls - Continued (See Section 6-2)
8 Arc Control LED
The LED lights to indicate the Arc Control
button is active. Light goes out when button is
inactive.
9 Arc Control Push Button
This push button allows fine tuning inductance
for MIG programs, and Arc Control for
programs other than MIG. When the push
button is pressed, the upper display (item 15)
shows INDU for inductance, or ARC for Arc
Control to indicate which parameter is
selected for change. The range of possible
values is 0-99 for inductance, and 0-50 for arc
control. Turn the Adjust knob to change the
parameter value. Press button to deactivate
arc control mode (LED goes out).
10 Wire Feed/Gas/Contactor LEDs
The Wirefeed LED lights when the wire feeder
is energized. For example, when the front
panel Jog or Retract button is pressed, the
Wirefeed LED lights.
12 Wire Feed Speed/Amps Display Push
Button
13 Lower Display
Press Wire Feed Speed/Amps Display button
to show weld amperage or wire feed speed in
lower display (the applicable LED under the
lower display lights to indicate which is
shown). When welding, actual value is shown.
If amperage was selected for display, the unit
will show actual welding amperage prior to
and while welding unless the the unit is in
Display Command Values mode. Only wire
speed command will be displayed while
welding if the unit is set in Display Command
Values mode, even if the Wire Feed
Speed/Amps Display button is pressed.
. Displays show actual or command values
as determined by configuration menu
when using a PDA with File Management/
WaveWriter software. Command values
are displayed prior to welding and actual
values are displayed while welding unless
a PDA with File Management/WaveWriter
software was used to set the unit in the
”Display Command Values” mode. In the
Display Command Values mode,
command values are displayed while
welding.
The Gas LED lights when the gas valve is
energized.
The Contactor LED lights when the output
contactor is energized, making the weld
output terminals live.
11 Wire Speed And Amps LEDs
The lit LED indicates whether wire speed or
amps are being displayed.
. If a PDA with File Management/WaveWriter
software is used to change wire feed units
(IPM, MPM) or display welding information
(command or actual),save the changes and
then turn the power to the unit off and then
on again for the changes to be carried out
by the unit.
14 Volts And Arc Adjust LEDs
The lit LED indicates whether voltage or arc
length is being displayed.
15 Upper Display
The upper display shows different information
depending on the active function of the unit
and the weld process being used. When the
display shows voltage (for a MIG process),
the Volts LED lights. When it shows arc adjust
[for a pulsed and RMD (optional) weld
process], the Arc Adjust LED lights. However,
during any weld process (MIG and pulse), the
unit will display actual arc voltage unless a
PDA with File Management/WaveWriter
software has set the unit in the ”Display
Command Values” mode.
16 Lock LED
• The lock LED is illuminated when one or more
programs have been locked using an optional
PDA with File Management/WaveWriter
software. This indicates that some programs
have been disabled. A disabled program will
not show up for selection.
Refer to the File Management/WaveWriter
Owner’s Manual for additional information.
Table 5-1. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2,
98% Argon/2% O2
CO2
C10
C15
C25
C5
OX5
OX2
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2
(81Ar/18HE/1CO2
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO 2
MIG/RMD/Accu-pulse)
OX2
Tri Gas
71, 76, 86R, 409,
439
90% Argon/10% CO2
C10
98% Argon/2% O2
OX2
4XXX, 5XXX
100% Argon
ARGN
Cored Tubular Wire
Aluminum
MCOR
ALUM
* Not all wire types may be available with your unit.
OM-231 185 Page 28
Tri Gas
Table 5-2. Robot Abbreviations
Manufacturer
Robot Abbreviation
ABB
ABB
Fanuc
FANU
Daihen
DAHN
Kawasaki
KAWA
Kuka
KUKA
Comau
COMU
Hitachi
HCHI
Nachi
NCHI
Panasonic
PANA
Motorman
MOTO
Robot Adapter
DTEC
Detect Disabled
OFF
None
Robt DTEC
6-4. Front Panel Switches
6
3
4
1
8
5
9
7
Ref. 803 677-A
2
1 Power Switch
Turns unit On or Off.
AUTO
300
The power-up sequence may last up to 30
seconds before the unit is ready to weld.
During power-up, the front panel will display
messages indicating the status of the unit. The
first message is:
AUTO 300 indicates the software being
loaded.
NET
WAIT
2
Contactor LED
Contactor LED illuminates when weld output is
energized.
NET WAIT is an abbreviation for ”network
updating” and means the internal control
network is powering up. The next message is
3
Purge Push Button
XXXX (Robot Type)
4
XXXX identifies the robot adapter being used
as identified by the unit (see Table 5-2 for a list
of robot adapters that could be displayed). To
ensure proper operation of the system, verify
the robot displayed corresponds to the actual
robot being used. The final message is
Gas LED illuminates when Purge push button
is pressed.
Press button to purge gas line.
Gas LED
6
Wirefeed LED
Wirefeed LED illuminates when wire feeds or
retracts.
7
Retract Push Button
Press button to retract wire. Wirefeed LED
illuminates when Retract push button is
pressed.
Auto-Threading feature is activated by
pressing the Jog and Retract buttons
simultaneously. Pressing the Jog, Purge, or
trigger switch will turn off the Auto-Threading
feature.
Jog Push Button
8
PDA Port
Press button to jog wire.
9
PC Port
5
OM-231 185 Page 29
6-5. Robot Calibration Mode
Use the robot calibration mode to
custom-calibrate the power source to
the robot command signals. This
ensures the wire speed, voltage, and
arc adjust are the same on the robot
pendant as on the power source.
XXXX
. The factory recommendation is to
perform the calibration on all
installations or code updates.
V
A
Follow this procedure if the factory
settings are not as accurate as
desired. Synchronization of the robot
and power source signals makes
installation easier and improves the
operation of the system.
A
Setup
Adjust
Arc Control
. The
robot pendant must have
Weld enabled, and there can be
no start/stop crater conditions set
in the robot.
Turn unit On. Unit displays abbreviated name of robot
detected where XXXX appears (see Table 5-2 for a list
of robot adapters that could be displayed).
The calibration mode will execute as a
”dry run” from the operator’s
perspective. The welding power
source provides the robot with
feedback so the robot thinks a weld is
underway, yet the robot torch need not
move during the calibration.
V
A
A
. If
you wish to stop the calibration
procedure, turn unit input power
off and then on again.
Setup
Adjust
If the calibration is performed correctly
the ROBT CAL message stop being
displayed; however, if it is performed
incorrectly, the message remains on
the display.
Arc Control
Press Wire Speed/Amps Display push button while abbreviated name
of robot appears to enter calibration mode. ROBT CAL message is
displayed. ROBT CAL message will not display until after the
power-up sequence is completed (approximately 20 seconds).
To start the calibration procedure over
again, turn unit input power off and
then on again following the calibration
setup steps following the calibration
setup steps.
CIRCULER
Use robot pendant or other method to enter two weld schedules into the
robot. Maintain schedule 1 for at least 10 to 20 seconds minimum before
moving on to schedule 2. Maintain schedule 2 for 10 to 20 seconds
before ending the simulated weld. Schedule data is shown below:
V
Schedule 1
A
Schedule 2
A
10.0 Volts
100 IPM
44.0 Volts
1000 IPM
Setup
Adjust
Arc Control
When the robot calibration mode ends, the
ROBT CAL message stops and the unit
will display normal front panel information.
OM-231 185 Page 30
219 712-A
6-6. Robot Auto-Calibration Sample Programs
. It is critical to make certain that NO start power, start conditions, run-in, or crater parameters of any kind are present in the robot program. The
welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this
as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second
condition and fail to execute Auto-Cal correctly.
Actual Motoman Welder Condition File
<Welding Current Output Char.>
NO.
REF (V)
MEASURE (A)
01
0.01
1
02
7.00
500
03
13.99
999
04
0.00
000
<Welding Voltage Output Char.>
NO.
REF (V)
MEASURE (V)
01
0.14
0.5
02
7.00
25.0
03
14.00
50.0
04
Sample Auto-Calibration Routine For Motoman Robot
0000
NOP
0001
Mov J
0002
AWELD 1.40
(AWELD direct input of 1.40Volts = 100 ipm)
0003
VWELD 2.80
(VWELD direct input of 2.80Volts = 10.0 volts)
0004
Arcon
0005
Timer T=10.00
0006
Arcof
0007
AWELD 14.00
(AWELD direct input of 14.00Volts = 1000 ipm)
0008
VWELD 12.32
(VWELD direct input of 12.32Volts = 44.0 volts)
0009
Arcon
0010
Timer T=10.00
0011
Arcof
0012
End
OM-231 185 Page 31
Sample Auto-Calibration Routine For Fanuc Robot
1: Call Safehome
2:
J P[1] 40% Fine
Arcstart [10.0Volts, 100.0IPM]
3:
L P[2] 10.0 sec Fine
Arc End [0.0Volts, 0.0IPM, 0.0Sec]
4:
Wait 1.00 (Sec)
5:
J P[3] 40% Fine
Arcstart [44.0Volts, 1000.0IPM]
6:
L P[4] 10.0 sec Fine
Arc End [0.0Volts, 0.0IPM, 0.0Sec]
7:
Call Safehome
Sample Auto-Calibration Routine For ABB Robot
Move J home, v500, z50, tweldgun;
Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
WaitTime 5;
Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd2, wv0, z50, tweldgun;
Move J home, v500, z50, tweldgun;
*Seam Data values must all be set at zero.
OM-231 185 Page 32
Weld Data 1:
Weld Data 2:
weld_sched:=0
weld_sched:=0
weld_speed:=5
weld_speed:=5
weld_voltage:=10
weld_voltage:=44
weld_wfs:=100
weld_wfs:=1000
org_weldspeed:=0
org_weldspeed:=0
org_weldvoltage:=0
org_weldvoltage:=0
org_weldwfeed:=0
org_weldwfeed:=0
6-7. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
. System configuration data will be
RST
lost during the Reset operation.
V
NO
Setup
A
A
Adjust
Arc Control
Enter reset mode by turning power On and pressing the Program
Push Button until the RST NO message is displayed. RST NO
message will not display until after the power-up sequence is
completed (approximately 20 seconds).
RST
V
YES
Setup
Adjust
RST
V
YES
A
A
Arc Control
Rotate Adjust knob to change NO
to YES.
Setup
Adjust
CYCL
V
PWRA
A
A
Setup
Arc Control
Adjust
A
Arc Control
Press the Arc Control button to
confirm the reset.
Cycl Pwr message appears on the display
when programs complete loading.
The reset message is displayed for
2 seconds while factory program
settings are being reloaded.
Turn power off, wait 10 seconds, and turn
power back on again to complete the reset
operation.
During the reset mode the following
factory default programs are loaded
into the unit:
Program 1
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3
Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
.052 Mild Steel
75% Argon, 25% CO2
. After
Reset is complete, be sure to load
appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation
219 712-A / 803 246-B
OM-231 185 Page 33
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
l Unreadable Labels
~ Weld Terminals
nl Cords
nl Gun Cables
Every
6
Months
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
l Damaged Gas Hose
Reference
nl Weld Cables
OR
~ Drive Rolls
~ Inside Unit
7-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 803 675-A
OM-231 185 Page 34
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read and follow these precautions.
8-1. Symbol Usage
OM-231 185M 2010−11 - Date, safety_stm 2010−03
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.
. Indicates special instructions.
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.
8-2. Servicing 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.
Only qualified persons should test, maintain, and repair this
unit.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D
Do not leave live unit unattended.
D
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXPLODING PARTS can injure.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
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.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
FALLING EQUIPMENT can injure.
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.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OM-231 185 Page 35
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep away from pinch points such as drive
rolls.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools
away from moving parts.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.
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.
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 install, test, and service
H.F. producing units.
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.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts from the manufacturer.
D Read and follow all labels and the Technical Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
8-3. 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.
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.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
8-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-231 185 Page 36
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
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.
SECTION 9 − TROUBLESHOOTING
9-1. Set Value Mode
V
A
A
1
Setup
Adjust
4
Arc Control
2
3
219 712-A
The Set Value mode is a troubleshooting tool
that allows certain robot command values to
be manually over-ridden.
1
Setup Push Button
2
Arc Control Push Button
3
Adjust Knob
4
Wire Feed Speed/Amps Display Push
Button
Enter the Set Value mode by pressing the
Setup and Arc Control push buttons at the
same time. When in the Set Value mode the
display windows briefly shows SET VALU and
the blinking LEDs under the display windows
indicate whether Volts, Arc Adjust, or Wire
Speed can be changed turning the Adjust
knob.
Depending on the defined weld process,
either volts (MIG) or arc adjust [pulse,
Accu-pulse, or RMD (optional)] can be
changed in the top display. Wire speed can be
changed in the bottom display. Press the Wire
Feed Speed/Amps push button to toggle
between selecting information in the top
display or bottom display. The LED under the
active display will blink to indicate the value
that can be changed.
Rotate the Adjust knob to change values.
Exit the Set Value mode by pressing the Setup
and Arc Control push buttons at the same time
or turning power source off and then back on
again.
OM-231 185 Page 37
9-2. Diagnostics
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
ERR
ERR
ERR
TACH
MOTR
WFS
STRT
STOP
FLOW
Indicates a
tachometer error.
Indicates a motor
error.
Indicates a wire
feed speed error.
Indicates an arc
start error.
Indicates an arc
stop error.
ERR
ERR
ERR
ERR
ERR
ERR
COOL
GND
STUK
TEMP
LINE
ARC
Indicates a coolant
flow error.
Indicates a ground
current error.
ERR TACH
• Tach error for Tach A occurs 2 seconds
after the loss of tachometer feedback. The
motor speed is regulated through the
monitoring of voltage and current. Press
Jog/Purge button to clear error.
• Tach error for Tach B occurs 2 seconds
after the loss of tachometer feedback. The
motor speed is regulated through the
monitoring of voltage and current. Press
Jog/Purge button to clear error.
ERR MOTR
• The motor error indicates that the motor
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle. Press Jog/Purge button to clear error.
ERR WFS
• The wire feed speed error indicates actual
wire feed speed does not match wire feed
speed command. Press Jog/Purge button
to clear error.
ERR STRT
• The start error, when enabled, occurs if the
trigger is held longer than three seconds
without an arc start. The error may be
cleared by releasing the trigger, and
pressing the Jog/Purge button.
OM-231 185 Page 38
Indicates a wire
stuck error.
Indicates a
temperature error.
Indicates a line
error.
Indicates a gas
flow error.
Indicates an arc
error.
ERR STOP
ERR STUK
• The stop error occurs as result of
obstructions in the wire feed system or a
faulty wire drive system. Check wire feed
and wire drive systems. Press Jog/Purge
button to clear error.
• The stuck error occurs if the welding wire
sticks to the workpiece at the end of a weld.
May be caused by poor weld conditions.
The error may be cleared by cutting wire
from workpiece, and pressing the Jog/
Purge button.
ERR FLOW
ERR TEMP
• The flow error indicates no gas flow to the
gun. The error may be reset by
reestablishing gas flow to the gun, and then
pressing the Jog/Purge button.
ERR COOL
• The cool error indicates no coolant flow in
water flow switch option. The error may be
reset by reestablishing coolant flow to the
gun, and then pressing the Jog/Purge
button.
ERR GND
• The ground current error occurs if weld
current is detected in the earth ground
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Turn
power off and back on to clear error.
• The temperature error indicates welding
power source has overheated and
shutdown. The error may be cleared by
allowing unit to cool down, and pressing the
Jog/Purge button. If problem persists,
check fan motors and thermistors for proper
operation. If unit is not overheated, check input line voltage. If input line voltage is okay,
contact nearest factory authorized Service
Agent.
ERR LINE
• The line error indicates input power is
outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.
ERR ARC
• The arc error indicates an arc outage
occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.
9-2.
Diagnostics (Continued)
WELD
MOTR
PLS
LOW
ROBT
E
WAIT
COM
WAIT
WFS
MEM
STOP
Indicates a weld
cycle wait error.
Indicates a motor
communication error.
Indicates a UIM
Indicates a low WFS
communication error. command error.
DEMO
OVER
UNIT
OVER
DONE
AVG
COMM
CRNT
Indicates RMD/Accuspeed demo is
expired.
Indicates an over
average current error.
Indicates a CRC
PCM bus error.
Indicates a CRC
robot memory error.
Indicates an
emergency stop error.
Indicates an
overcurrent error.
WELD WAIT
ROBT MEM
UNIT COMM
• The weld wait error indicates unit was not
ready for a weld sequence. Press Jog/
Purge button to clear error.
• The robot memory error indicates robot
lost memory data. Press Jog/Purge button
to clear error.
• The unit communication error indicates
the data bus on the PCM board is not
functioning properly. Press Jog/Purge
button to clear error.
MOTR COM
• The motor communication error indicates motor board lost data communications. Press Jog/Purge button to clear error.
If condition persists, contact nearest factory
authorized service agent.
PLS WAIT
• The uim communication error indicates
user
interface
board
lost
data
communications. Press Jog/Purge button
to clear error. If condition persists, contact
nearest factory authorized service agent.
LOW WFS
• The low wire feed speed error indicates
actual wire feed speed is lower than wire
feed speed command. Check for
obstructions in the wire feed system or a
faulty wire drive system. Press Jog/Purge
button to clear error.
E STOP
• The emergency stop error occurs if the
user presses an emergency stop button.
Reset the emergency stop button and press
Jog/Purge button to clear error. Only applies
to units equipped with E stop option.
DEMO DONE
• The DEMO done message indicates the
RMD and Accuspeed demos are completed. Pressing Jog/Purge button will change
the screen to CYCL PWR on the display.
Turn unit power off and back on again. RMD
and Accuspeed share the same demo timer.
If the time expires for one demo process,
both demo processes are deactivated.
OVER AVG
• The over average error indicates that
current is outside the average range for the
set program parameters. Check and correct
program parameters. Press Jog/Purge
button to clear error.
OVER CRNT
• The over current error indicates welding
power source primary current of the inverter
is too high. Turn welding power source off
and disconnect unit for servicing.
Attempting to reset the display to
continue welding may further damage
internal components. A complete
prepower check of the unit is needed
including resistance measurements of R1
and R8 resistors on welding power source
Interconnect board. Resistors should
measure 30K ohms. Visually inspect
electrolytic capacitors C1 and C2 for any
possible damage. In the event of an over
voltage condition, R1 and R8 could open
potentially causing an imbalance in the
power circuit. This condition would create
excessive current in the inverter primary
transformer and result in the OVER CRNT
error.
OM-231 185 Page 39
9-2.
Diagnostics (Continued)
REL
TRIG
ERR
TRIG
STUK
UNKN
Indicates a contactor Indicates a trigger
on error.
closed error.
REL TRIG
• The release trigger error indicates the
user held the gun trigger after an E stop was
reset causing the contactor to remain on.
Press Jog/Purge button to clear error.
TRIG STUK
• The trigger stuck error indicates the user
held the gun trigger during power up.
Release trigger and turn power off and back
on.
OM-231 185 Page 40
Indicates an
unknown error.
ERR UNKN
• The unknown error indicates an error was
sent from the PCM board to the UIM, but
error condition is unknown. Make sure
welding power source is isolated from the
welding fixture. Press Jog/Purge button to
clear error.
9-3. Removing Cover and Measuring Input Capacitor Voltage
Tools Needed:
!
Turn Off welding power
source, and disconnect input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
1
5/16 in.
2
Remove cover
+ lead to left bus terminal, − lead to right bus terminal
1
Power Interconnect Board
PC2
2
Voltmeter
Measure the DC voltage across the
+ bus terminal and − bus terminal on
PC2 as shown until voltage drops to
near 0 (zero) volts. Measure input
capacitor voltage on inverter
assembly before proceeding.
3
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit.
Reinstall cover when finished.
3
Typical Bleeder Resistor
25 to 1000 ohm, 5
watt resistor
#16 AWG 1000 volts
DC insulation rating,
approx 3 in. (76 mm)
leads
802 985 / Ref. 803 679-B
OM-231 185 Page 41
9-4. Process Control Module PC4 Diagnostic LEDs
1
Process Control Module PC4
Diagnostic LEDs are visible inside unit,
located on PC4 mounted on the top tray.
Refer to Section 9-5 for information on
diagnostic LEDs.
1
Reinstall cover after checking diagnostic
LEDs.
LED1
LED2
LED3
LED4
216 956-A / Ref. 803 679-B
9-5. Diagnostic LEDs On Process Control Module PC4
LED
Status
1
On
Indicates −25 volts DC is present on process control module PC4
Off
Indicates −25 volts DC is not present on process control module PC4
On
Indicates +25 volts DC is present on process control module PC4
Off
Indicates +25 volts DC is not present on process control module PC4
On
See Network Status Table in Section 9-12
Off
See Network Status Table in Section 9-12
2
3,4
OM-231 185 Page 42
Diagnosis
9-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings
1
2
Wire Feed Module PC6
Diagnostic LEDs are visible inside
unit, located on PC6 mounted on
the top tray assembly.
Refer to Section 9-7 for information
on diagnostic LEDs.
Reinstall top cover after checking
diagnostic LEDs.
1
LED1
LED2
2
Dip Switch S1
Dip switches are used to identify
each circuit board on the internal
network. Dip switch settings are
different for each circuit board. For
proper operation, do not change dip
settings from those shown.
LED3
LED4
217 333-B / 804 756-A
9-7. Diagnostic LEDs On Wire Feed Module PC6
LED
Status
1
On
Indicates +15 volts DC is present on wire feed module PC6
Off
Indicates +15 volts DC is not present on wire feed module PC6
On
Indicates +5 volts DC is present on wire feed module PC6
Off
Indicates +5 volts DC is not present on wire feed module PC6
On
See Network Status Table in Section 9-12
Off
See Network Status Table in Section 9-12
2
3,4
Diagnosis
OM-231 185 Page 43
9-8. User Interface Module PC7 Diagnostic LEDs
2
LED1
LED2
3
1
218 559-A / 804 756-A
1 User Interface Module PC7
Diagnostic LEDs are visible inside unit,
located on PC7 mounted behind the front
panel.
Refer to Section 9-9 for information on
diagnostic LEDs.
Reinstall cover after checking diagnostic
LEDs.
2
Dip Switch S1
3
Dip Switch S2
9-9. Diagnostic LEDs On User Interface Module PC7
LED
Status
1, 2
On
See Network Status Table in Section 9-12
Off
See Network Status Table in Section 9-12
OM-231 185 Page 44
Diagnosis
Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.
9-10. Automation Interface Module PC9 Diagnostic LEDs
1
LED11
LED13 LED25
LED28
LED12
LED14
LED27
LED31
LED30
LED1
LED2
LED3
LED4
2
LED5
LED6
LED7
LED8
LED9
LED10
LED32
LED33
LED15
LED20 LED19 LED18 LED16
LED17
LED21 LED22 LED23 LED24 LED26 LED29
216 958-A / Ref. 803 679-B
1 Automation Interface Module PC9
Diagnostic LEDs are visible inside unit,
located on PC9 mounted on left side.
Refer to Section 9-11 for information on
diagnostic LEDs.
Reinstall cover after checking diagnostic
LEDs.
2
Dip Switch S3
3
Dip Switch S4
Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.
OM-231 185 Page 45
9-11. Diagnostic LEDs On Automation Interface Module PC9
LED
Status
1
On
Input signal On from robot for jog advance
Off
Input signal Off from robot for no jog advance
On
Input signal On from robot to energize contactor
Off
Input signal Off from robot to not energize contactor
On
Input signal On remote program A selected
Off
Input signal Off remote program A not selected
On
Input signal On remote program C selected
Off
Input signal Off remote program C not selected
On
Input signal On from E-stop board PC12 for no emergency stop
Off
Input signal Off from E-stop board PC12 acknowledges E-stop is On from robot
On
Spare 1 not assigned
Off
Spare 1 not assigned
7
On
Input signal On Autoset-C selected
Off
Input signal Off Autoset-C not selected
8
On
Input signal On Autoset-B selected
Off
Input signal Off Autoset-B not selected
On
Input signal On Remote Jog on from peripheral plug
Off
Input signal Off Remote Jog off from peripheral plug
10
On
Input signal On Remote Purge on from peripheral plug
Off
Input signal Off Remote Purge off from peripheral plug
11
On
Input signal On from robot for jog retract
Off
Input signal Off from robot for no jog retract
On
Input signal On from robot for purge
Off
Input signal Off from robot for no purge
13
On
Input signal On remote program B selected
Off
Input signal Off remote program B not selected
14
On
Input signal On Touch Sensor on from robot or peripheral plug
Off
Input signal Off Touch Sensor off from robot or peripheral plug
On
Spare 0 not assigned
Off
Spare 0 not assigned
16
On
Spare 2 not assigned
Off
Spare 2 not assigned
17
On
Input signal On Autoset-A selected
Off
Input signal Off Autoset-A not selected
On
Input signal On Autoset-D selected
Off
Input signal Off Autoset-D not selected
On
Input signal On Remote Retract on from peripheral plug
Off
Input signal Off Remote Retract off from peripheral plug
On
Input signal On Remote Water Flow on from peripheral plug
Off
Input signal Off Remote Water Flow off from peripheral plug
On
Input signal On from robot for no emergency stop
Off
Input signal Off from robot for emergency stop
On
Input signal On from relay K3 for welding power source ready and no detected errors present
Off
Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is
in operating mode preventing the weld ready signal from being enabled
2
3
4
5
6
9
12
15
18
19
20
21
23
OM-231 185 Page 46
Diagnosis
LED
Status
24
On
Input signal On from relay K4 to indicated wire stuck in weld joint
Off
Input signal Off from relay K4 to indicate wire is not stuck in weld joint
25
On
Indicates +5 volts DC is present on automation interface module PC9
Off
Indicates +5 volts DC is not present on automation interface module PC9
26
On
Input signal on from relay K5 for flow (shielding gas or coolant) present
Off
Input signal off from relay K5 for flow (shielding gas or coolant) not present
On
Indicates −15 volts DC is present on automation interface module PC9
Off
Indicates −15 volts DC is not present on automation interface module PC9
28
On
Indicates +15 volts DC is present on automation interface module PC9
Off
Indicates +15 volts DC is not present on automation interface module PC9
29
On
Input signal on from relay K6 for arc detected
Off
Input signal off from relay K6 for no arc detected
On
See Network Status Table in Section 9-12
Off
See Network Status Table in Section 9-12
32
On
Input signal on for aux. relay energized
Off
Input signal off for aux. relay energized
33
On
Input signal on touch sensor touch detected
Off
Input signal off touch sensor touch not detected
27
30, 31
Diagnosis
9-12. Network And Module Status LEDs
A. Network Status LEDs
The following are network status LEDs:
LED1 on the UIM circuit board
LED4 on the WFM and PCM circuit boards
LED30 on the AIM circuit board.
Status
Off
Green
Flashing Green
Red
Diagnosis
The circuit board is not on-line with the network or there is no power applied to the circuit board.
The circuit board is operating normally and the on-line connection is made with the network.
The circuit board is waiting for an on-line connection to be made with the network.
The circuit board has encountered a communication link failure with the network. Check DeviceNet cable connections. Verify
dip switch positions according to Sections 1-2 and 1-3. Replace circuit board if necessary.
B. Module Status LEDs
The following are module status LEDs:
LED2 on the UIM circuit board
LED3 on the WFM and PCM circuit boards
LED31 on the AIM circuit board.
Status
Off
Green
Flashing Red
Red
Diagnosis
There is no power applied to the circuit board or the board software is not executing its functions.
The circuit board is operating normally.
The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.
The circuit board has encountered an unrecoverable fault.
OM-231 185 Page 47
9-13. Troubleshooting
Trouble
No weld output; completely inoperative
Remedy
Place line disconnect in On position (see Section 5-14).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-14).
Check for proper input power connections (see Section 5-14).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 5-10).
errors displayed.
Check that proper program for wire size, process, and shielding gas is loaded.
Clean and tighten all weld connections.
No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1.
Wire does not feed.
Check supplementary protector CB2 and reset if necessary.
Check motor control cable connections.
Wire feeds erratically.
Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Check voltage sense lead connection, clean and tighten if necessary.
Gas does not flow or does not stop flow- Check gas valve and flow meter.
ing; wire feeds.
Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.
using electrode negative (straight
polarity) process.
OM-231 185 Page 48
SECTION 10 − ELECTRICAL DIAGRAMS
231 104-C (Part 1 Of 2)
Figure 10-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)
OM-231 185 Page 49
Figure 10-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)
OM-231 185 Page 50
231 104-C (Part 2 Of 2)
OM-231 185 Page 51
Figure 10-3. Circuit Diagram For 72 Pin Robot Interface
OM-231 185 Page 52
219 266-C
OM-231 185 Page 53
Figure 10-4. Circuit Diagram For Peripheral/Motor Interface
OM-231 185 Page 54
219 267-B
OM-231 185 Page 55
SECTION 11 − PARTS LIST
. Hardware is
common and
not available unless listed.
2
1
3
6 − Fig 11-4
4 − Fig 11-3
7
18
20
5 − Fig 11-2
19
19
21
13
17 − Fig 11-5
14
12
11
10
9
7
8
16
15
Ref. 804 751-B
Figure 11-1. Main Assembly
OM-231 185 Page 56
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . 210492
. . . 2 . . . . . T2 . . . . . . . 212543
. . . 3 . . . . . . . . . . . . . . . . 210481
. . . 4 . . . . . . . . . . . . . . . . Fig 11-3
. . . 5 . . . . . IM1 . . . . . . 214597
. . . . . . . . . . . IM1 . . . . . . 242680
. . . 6 . . . . . . . . . . . . . . . . Fig 11-4
. . . 7 . . . . . . . . . . . . . . . . 230260
. . . 8 . . . . . . . . . . . . . . . . 210482
. . . 9 . . . . . . . . . . . . . . . . 220200
. . . 10 . . . . HD2 . . . . . . 182918
. . . 11 . . . . . . . . . . . . . . . . 220377
. . . 12 . . . . . . . . . . . . . . . . 204846
. . . 13 . . . . PC14 . . . . . . 229967
. . . 14 . . . . . . . . . . . . . . . . 148025
. . . 15 . . . . . . . . . . . . . . . . 220376
. . . 16 . . . . . . . . . . . . . . . . 226550
. . . 17 . . . . . . . . . . . . . . . . Fig 11-5
. . . . . . . . . . . . . . . . . . . . . . 227855
. . . 18 . . . . . . . . . . . . . . . . 010467
. . . 19 . . . . . . . . . . . . . . . . 225840
. . . 20 . . . . . . . . . . . . . . . . 010916
. . . 21 . . . . . . . . . . . . . . . . 247392
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, LH w/Components (Fig 11-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (Fig 11-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Kit, Connectors W/Washer For Power Cables (Includes) . . . . . . . . . . . .
. . . . Connector, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Reducer 1.25 in − 0.75 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector, Clamp Cable 0.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-231 185 Page 57
14
. Hardware is
common and
not available unless listed.
15
2
1
3
4
5
13
6
12
7
8
11
9
33
10
6
34
35
7
17
16
18
19
32
31
20 21
30
29
23
24
25
23
27
13
36
28
26
22
23
38
37
802 955-A
Figure 11-2. Windtunnel Assembly LH And RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Windtunnel Assembly LH And RH (Fig 11-1 Item 6)
... 1 ................
... 2 ................
. . . 3 . . . . . L1 . . . . . . .
... 4 ................
. . . 5 . . . R3, C4 . . . . .
... 6 ................
. . . 7 . . . D1, D2 . . . . .
... 8 ................
... 9 ................
. . . 10 . . . . . T1 . . . . . . .
. . . 11 . . . . . Z1 . . . . . . .
. . . 12 . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . .
......................
......................
. . . . . . . . . . CT1 . . . . . .
. . . 20 . . . . . . . . . . . . . . . .
. . . 21 . . . C1, C2 . . . . .
. . . 22 . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . .
. . . 24 . . RT1, RT2 . . . .
OM-231 185 Page 58
214597
196351
213940
214519
233052
199840
201531
196347
196349
203408
220496
170647
179276
196355
010546
242680
196332
030170
196259
115092
115091
196231
201695
226081
210507
217625
214015
. . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . .
. . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
1
3
6
1
1
1
2
1
1
1
1
2
2
2
2
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Windtunnel Assembly LH And RH (Continued)
(Fig 11-1 Item 6)
. . . 25 . . . . PC2 . . . . . .
. . . 26 . . . . . C3 . . . . . . .
. . . 27 . . . . . . . . . . . . . . . .
. . . 28 . . . . HD1 . . . . . .
......................
. . . 29 . . . R1, R2 . . . . .
......................
. . . 30 . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . .
. . . 34 . . . . . L2 . . . . . . .
. . . 35 . . . . . . . . . . . . . . . .
......................
......................
. . . 36 . . . . PC1 . . . . . .
. . . 37 . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . .
237370
196143
196378
182918
196384
196343
196840
109056
196514
196512
196330
196345
196588
196365
199136
239618
204846
083147
. . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . .
. . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . .
. . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Control (Inverter 400A) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-231 185 Page 59
. Hardware is
common and
not available unless listed.
1
2
3
4
5
11
6
10
7
9
8
802 916-C
Figure 11-3. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Top Tray Assembly (Fig 11-1 Item 4)
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
. . . . PC12 . . . . . .
. . . . PC3 . . . . . .
................
................
................
. . . . PC4 . . . . . .
................
................
................
................
. . . . PC6 . . . . . .
239623
239598
210490
134201
083147
239599
170647
210491
223439
198122
239601
. . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . .
. . . Process Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . .
. . . Wire Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
4
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-231 185 Page 60
. Hardware is
common and
not available unless listed.
8
5
9
7
6
4
3
2
1
10
15
11
12
14
13
803 681-B
Figure 11-4. Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Rear Panel Assembly (Fig 11-1 Item 8)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
. . . . PC9 . . . . . .
................
. . . . PC10 . . . . . .
................
................
................
................
................
................
................
. . . . CB1 . . . . . .
. . . . CB2 . . . . . .
. . . . PC11 . . . . . .
. . . . RC2 . . . . . .
................
239600
212628
239627
207676
217297
210479
210358
210505
201058
210483
083432
093995
239631
604176
216596
. . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 6-32 x 1.000 lg .250 hex nyl fem . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 6-32 x .250 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . Circuit Card Assy, Motor Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
4
1
1
1
1
1
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-231 185 Page 61
. Hardware is
common and
not available unless listed.
2
22
11
1
7
21
4
20
5
3
19
7
6
8
18
9
10
17
7
11
14
12
13
15
16
16
803 682-B
Figure 11-5. Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Front Panel Assembly (Fig 11-1 Item 14)
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
. . . . . S1 . . . . . . .
................
................
................
. . . . . FM . . . . . . .
. . . . PC13 . . . . . .
. C6, C7, C8 . . .
. . . . RC5 . . . . . .
................
OM-231 185 Page 62
207456
207895
179851
233576
196313
239619
206878
214664
216965
. . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . .
. . . Panel, PC Card Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy,ISO/COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
3
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Front Panel Assembly (Fig 11-1 Item 14) (Continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
10
11
12
13
14
15
16
17
18
19
20
21
22
................
................
................
................
................
................
................
PB1, PB2, PB3 . .
................
................
................
................
................
216966
213102
210866
210477
219843
207979
186621
199443
231056
212779
210865
210483
210358
. . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . .
. . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . .
. . . Knob, Black Electroswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
2
3
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-231 185 Page 63
Notes
Effective January 1, 2011
(Equipment with a serial number preface of MB or newer)
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.
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 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
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.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
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.
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.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4) payment
of or credit for the purchase price (less reasonable depreciation
based upon actual use) upon return of the goods at customer’s risk
and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of any
kind will be allowed.
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.
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.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2011−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2011 Miller Electric Mfg. Co.
2011−01