Miller Electric D-74DX Owner`s manual

OM-1500-7
204 129Q
2011−02
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
D-74DX
CE
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com
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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Equipment Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Wire Type, Size, And Feed Speed Capability Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Power Source Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Left/Right Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Jog/Purge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Optional Dual Schedule Switch Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Diagnostics For User Defined Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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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:
Product
Stock Number
D­74DX FEEDER
300621
D­74DX FEEDER W/HIGH SPEED MOTORS
300621001
D­74DX FEEDER W/CE,EURO
300621002
D­74DX FEEDER W/CE,EURO,HIGH SPEED MOTOR
300621003
Council Directives:
• 2006/95/EC Low Voltage
• 2004/108/EC Electromagnetic Compatibility
Standards:
•
•
•
•
IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
IEC 60974­5:2007 Arc welding equipment – Part 5: Wire feeders
IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
EN 50445:2008 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)
Signatory:
December 21, 2010
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
241324D
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.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can 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.
OM-1500-7 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
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.
OM-1500-7 Page 2
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING 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-1500-7 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-1500-7 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-1500-7 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-1500-7 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-1500-7 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-1500-7 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-1500-7 Page 9
OM-1500-7 Page 10
SECTION 3 − DEFINITIONS
3-1. WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) 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.
3-2. Symbols And Definitions
. Some symbols are found only on CE products.
A
IP
Amperes
V
Hz
Alternating Current
Hertz
Program
Wire Feed
Jog
Output
Trigger
Line Connection
Set Up
Sequence
Trigger Hold On
Trigger Hold Off
Purge
Press To Set
Start
Crater
Time
Preflow Time
Postflow Time
Read Instructions
Degree Of
Protection
I1
Increase
U1
X
Volts
Primary Voltage
A
B
Primary Current
I2
Rated Current
U2
Duty Cycle
Load Voltage
Dual Schedule
OM-1500-7 Page 11
SECTION 4 − INTRODUCTION
4-1. Specifications
Type of Input
Power
Welding Power
Source Type
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Constant Voltage (CV)
DC With 14-Pin And
Contactor Control
Wire Feed Speed
Wire Diameter
Range
Standard: 50 To 780
ipm (1.3 To 19.8 mpm)
.023 To 1/8 in.
(0.6 To 3.2 mm)
Optional High Speed:
92 To 1435 ipm (2.3
To 36.4 mpm)
Optional Low Speed:
19 to 300 ipm
(0.4 to 7.6 mpm)
Max Spool
Capacity:
18 in. (457 mm)
Welding
Circuit
Rating
100 Volts,
750
Amperes,
100% Duty
Cycle
IP
Rating
Overall
Dimensions
Weight
IP 21S
Length: 35 in.
(889 mm)
87 lb
(39.5 kg)
Max Spool
Weight: 60 lb
(27 kg)
Width: 12-1/2 in.
(318 mm)
Height: 14 in.
(356 mm)
SECTION 5 − INSTALLATION
5-1. 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.
ce-emc 3 2010-10
5-2. 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.
Notes
OM-1500-7 Page 12
5-3. Site Selection
3
!
Do not put feeder where
welding wire hits cylinder.
!
Do not move or operate
equipment when it could tip.
1
Wire Feeder
2
Rubber Feet
Choose slot that allows all rubber
feet to sit securely on top of welding
power source.
4
1
5
3
Wire Spool/Reels
4
Gas Cylinder w/Hose And
Regulator (Customer
Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
2
5
Welding Power Source
6
Running Gear
. Factory voltage settings are V-
Min 10 and V-Max 38. If you are
using a power source with a different voltage range, see Section 5-9 for V-Min And V-Max
adjustments.
6
. Wire feeder shown is representative
only and does not reflect actual unit.
Ref. 803 053
OM-1500-7 Page 13
5-4. Equipment Connection Diagrams
1
Welding Power Source
2
Contactor Control/Power Cord
3
Positive (+) Weld Cable
4
Negative (−) Weld Cable
5
Workpiece
6
Welding Gun
7
Wire Feeder
8
Gas Hose
9
Gas Cylinder and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
1
9
2
3
4
5
8
7
6
803 073
OM-1500-7 Page 14
5-5. Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable - 10 Ft
(3.0 m)
Shielding Gas Valve Fittings
Requires fitting with 5/8-18 righthand threads. Connect customersupplied gas hose.
3
4
5
6
7
Weld Cable Terminal
Jumper Weld Cable
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
To rotate the drive assembly, loosen drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
2
1
3
5
4
4
5
6
7
Tools Needed:
9/16, 5/8 in.
3/16 in.
803 067 / 802 825-A
OM-1500-7 Page 15
5-6. 14-Pin Plug Information
Pin*
I
G
A
24 volts AC with respect to socket G.
A
B
Contact closure to A completes 24 volts AC contactor control circuit.
B
L C
M D
E
G
Circuit common for 24 volts AC circuit.
C
+10 volts DC input from power source to wire feeder with respect to socket D.
D
Remote control circuit common.
E
0 to +10 volts DC output signal from wire feeder to power source with respect to socket D.
H
Voltage feedback; 0 to +10 volts DC, 1 volt per 10 arc volts.
F
Current feedback; 0 to +10 volts DC, 1 volt per 100 amperes.
J
H
K
N
F
Pin Information
*The remaining pins are not used.
5-7. Wire Type, Size, And Feed Speed Capability Table
Motor Speed
Wire Type
Wire Size
Rated Speed Range (per IEC 60974-5)
Standard
All
.023 To 5/64 in. (0.6 To 2 mm)
55 To 770 ipm (1.4 To 19.6 mpm)
Standard
All
3/32 To 7/64 in. (2.4 To 2.8 mm)
55 To 700 ipm (1.4 To 17.8 mpm)
Standard
All
1/8 in. (3.2 mm)
55 To 300 ipm (1.4 To 7.6 mpm)
Optional High
Speed
All
.023 To 5/64 in. (0.6 To 2 mm)
92 To 1435 ipm (2.3 To 36.4 mpm)
Optional Low
Speed
All
.023 To 1/8 in. (0.6 To 3.2 mm)
19 To 300 ipm (0.4 To 7.6 mpm)
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-1500-7 Page 16
5-8. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Adjust
Rear
Rolls
Pressure
Indicator
Scale
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Tools Needed:
Drive Rolls
Back Of Gun
3/16, 5/64 in.
15/16, 3/8 in.
End Of Liner
. For best wire feeding performance, be
sure that the outlet cable has the proper
size liner for the welding wire size being
used. Also, when the gun is installed, the
liner extending from the back of the gun
should be as close to the drive rolls as
possible, without touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
. For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in. (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If contact tip is completely blocked, wire should
slip at the feeder (see pressure adjustment above).Cut wire off. Close cover.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A
OM-1500-7 Page 17
5-9. Power Source Selection Menu
1
2
Non-CE Model Shown
. When the feeder is turned on,
1
Program
Volts
Upper Display
Lower Display
the Power Source Selection
Menu allows the operator to select a default power source.
Selecting a default power
source, automatically sets the
correct Vmin and Vmax settings for adjusting the output
voltage of the power source.
Time (sec)
First Time Feeder Is Turned On
Wire Speed
Amps
Start
Trigger Hold
Crater
Pre/Postflow
Sequence
* * Power Source
The feeder automatically goes into
the Power Source Selection Menu.
The feeder displays “dELT” on the
Upper Display and “452” on the
Lower Display, meaning that a Deltaweld 452 is the default power
source, and has a voltage range of
10V as Vmin and 38V as Vmax.
2
Dual Schedule
Adjust
Upper Display
Setup
Lower Display
Voltage Range
Deltaweld 452
dELT
452
Vmin =10
Vmax =38
Deltaweld 302
dELT
302
Vmin =10
Vmax =32
Deltaweld 652
dELT
652
Vmin =10
Vmax =44
Dimension 302
dIM
302
Vmin =10
Vmax =32
Dimension NT 450
dIM
450
Vmin =10
Vmax =38
Dimension 452
dIM
452
Vmin =10
Vmax =38
Dimension 652
dIM
652
Vmin =10
Vmax =65
Dimension 1000
dIM
1000
Vmin =10
Vmax =60
XMT 304
XMT
304
Vmin =10
Vmax =35
XMT 350
XMT
350
Vmin =10
Vmax =38
XMT 456
XMT
456
Vmin =10
Vmax =38
Invision 350 MPa
I350
MPa
Vmin =10
Vmax =38
Invision 354MP
I354
MP
Vmin =10
Vmax =35
Invision 456MP
I456
MP
Vmin =10
Vmax =38
Invision 456P
I456
P
Vmin =10
Vmax =38
PHOENIX 456
PHX
456
Vmin =10
Vmax =38
SUMMIT ARC 1000
SUM
1000
Vmin =25
Vmax =44
** For any power sources not listed, pick a matching voltage range, or see Sec 5-12 to
set Vmin and Vmax.
OM-1500-7 Page 18
At power up, the operator has three
seconds to select a default power
source from the list shown on the
display. Operator may scroll
through the list of power sources by
using the Adjust control. After selecting a power source the operator
has three seconds to change to a
different power source or begin
welding. After making a power
source selection, the operator may
press the Program Button to avoid
having to wait the three seconds.
When turning off the feeder, the default power source will be retained.
If voltage settings have already
been set with the Vmin and Vmax in
the Auxiliary Menu, selecting a default power source with the Power
Source Selection Menu overrides
the Vmin and Vmax voltage settings.
Next Time Feeder Is Turned On
The feeder will display the last selected default power source. The
operator has three seconds to select another power source, or press
the Program Button to exit the Power Source Selection Menu.
Disabling The Power Source
Selection Menu
Once the default power source has
been selected the Power Source
Selection Menu may be disabled
using the Auxiliary Menus. See
Section 6-12.
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this wire feeder:
General Terms:
Cold Wire Jog
Feeding wire without contactor or gas valve being energized.
Sequence
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
Weld Program
A group of sequences that make up a weld cycle.
6-2. Power Switch
1
Power Switch
1
Ref. 803 072
6-3. Left/Right Select Switch
1
Left/Right Select Switch
Pressing the Left/Right Select
switch allows the operator to
choose which side of the units’ controls will operate.
. Depressing the Left or Right
Gun Trigger also allows the
operator to enable the controls on that side of the unit.
1
Ref. 803 053
OM-1500-7 Page 19
6-4. Jog/Purge Switch
1
2
3
Jog/Purge Switch
Adjust Control
Gun Trigger Receptacle
2
3
Ref. 803 053
1
Pressing the Jog/Purge switch allows the operator to jog wire without energizing the weld
power or gas valve circuit.
• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog operation for a maximum of two minutes. If the gun
trigger is still activated after two minutes, the
jog operation is terminated to prevent complete despooling of the wire, in the case of
a damaged gun.
• The unit displays the “ERR TRIG“ message
to inform the operator that the trigger is activated.
• Jog speed can be adjusted by the Adjust
control when the unit is jogging wire. The
unit displays jog speed when the unit is being jogged.
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before welding and to preset gas pressure at the
regulator.
6-5. Front Panel Controls
Nameplate
See
Section
6-7
See
Section
6-6
See
Section
6-8
See
Section
6-11
OM-1500-7 Page 20
See
Section
6-10
See
Section
6-9
6-6. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
Program Push Button
Press button to activate program
select feature. To change the program number, press the Program
push button and rotate the Adjust
control.
1
3
3
Program Push Button LED
The LED lights to indicate the Program push button is active.
2
6-7. Upper Display
3
1
2
4
5
. To set the correct voltage range for a par-
ticular power source, see Section 5-9 for
power source selection menu, or Section
6-12 for V-Min And V-Max adjustments.
1 Upper Display
The upper display shows voltage or time. The
unit displays both preset and actual arc voltage. When the unit is in a welding state, actual
arc voltage is displayed. The upper display
shows welding sequence time when the Time
LED is illuminated.
2 Upper Display Push Button
Press and hold button to adjust or display weld
time. Release button to display voltage.
3 Upper Display Push Button LED
The upper display push button LED illuminates to indicate that information displayed
can be changed by the Adjust control.
4 Volts LED
5 Time LED
The LEDs below the display illuminate to indicate which value is being shown.
At any time while welding, the unit permits the
adjustment of the weld sequence voltage and
overrides the display of actual arc voltage.
• If the unit is displaying a welding sequence
that can be timed, the welding time display
mode is entered by pressing the upper dis-
play push button repeatedly until welding
time is the active parameter in the upper display. At idle, the upper display toggles between showing weld voltage or weld time,
with subsequent presses of the upper display push button.
• The unit defaults to displaying welding voltage when a welding sequence display
mode is first entered.
• If the weld sequence has a time set (as in
spot time), after the weld program is completed, ERR TRG 1 will be displayed to indicate the weld program is complete. Release
trigger to clear error.
OM-1500-7 Page 21
6-8. Lower Display
3
1
2
4
5
1
Lower Display
to indicate that information displayed can be
changed by the Adjust control.
The lower display shows wire speed or
amperage. The unit displays and adjusts only
preset wire speed at idle. When the unit is in
a welding state, actual wire speed is displayed
for the active welding sequence.
2
4
5
The LEDs below the display illuminate to indicate which value is being shown.
Lower Display Push Button
• If the unit is in a welding state that does not
involve feeding wire, the unit displays the
weld sequence wire speed. At any time during welding, the weld sequence wire speed
can be adjusted and overrides the preset
wire speed display. In other words, if the Ad-
Press button to choose between wire speed or
amperage functions.
3
Wire Speed LED
Amps LED
Lower Display Push Button LED
The lower display push button LED illuminates
just control is activated while welding, the
unit displays and permits adjustment of the
weld sequence wire feed speed regardless
of the active welding sequence.
• When the unit is displaying amperage, the
Amps LED illuminates. Amperage is only
displayed if the unit is in a welding state and
the amperage is above a minimum value of
25 Amps.
• The display will read dashes for amperage
readings below the amperage threshold,
prior to arc initiation.
6-9. Setup Push Button
3
4
2
1
1 Setup Push Button
Press button to choose between trigger hold
or dual schedule functions.
2 Setup Push Button LED
3 Trigger Hold LED
4 Dual Schedule LED
• When the Setup button is pressed, the Setup push button LED flashes and the Trigger
Hold LED flashes.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
the upper display indicates HOLD and the
lower display indicates the trigger hold status On/Off. Use the Adjust control to change
OM-1500-7 Page 22
the trigger hold status or press the lower display push button. If trigger hold is turned On,
the trigger hold LED illuminates and stays
On.
• When trigger hold is On, the user must
press and hold the trigger for a predefined
amount of time (the trigger hold delay time−
see Section 6-12), then release it for the trigger hold function to be active. To shut off the
weld when trigger hold is On, the user must
press and release the trigger.
• If a weld time is programmed, trigger hold is
disabled.
• Trigger hold and dual schedule cannot be
used concurrently.
• When the Setup button is pressed a second
time, the dual schedule LED flashes. In this
mode the upper display indicates DUAL and
the lower display indicates dual schedule
status On/Off. Use the Adjust control to
change the dual schedule status if desired.
• Pressing the Setup button again exits the
Setup mode. The dual schedule LED stops
flashing to indicate the dual schedule status
is Off.
• While in the Setup mode, the active program
can be adjusted without deactivating the
trigger hold Setup mode operation. If the
trigger is activated, Setup mode(s) is terminated.
6-10. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parameters, and to select various sequences. Refer to the section for
the function in question for information related to using the Adjust control.
1
6-11. Sequence Push Button
3
Start
Time
2
Preflow
Time
Weld
Time
Crater
Time
Postflow
Time
1
Welding Sequence Diagram
1
2
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
When the unit enters a welding state, all sequence display modes are terminated and
the weld display mode is activated.
. For more information on Setting
If zero time is programmed for a timed sequence except for Weld, that sequence will
be skipped.
Sequence Parameters see Section 7-1.
• The Sequence push button allows the
selection of welding sequences. Five welding sequences are available. The default
sequence is the Weld sequence. The Weld
sequence is active on power up. Three
welding sequence LEDs are located above
the Sequence push button: Start, Crater,
and Preflow/Postflow. The applicable LED
illuminates to indicate which welding sequence is active.
• The LED illuminates to indicate that a welding sequence display mode other than Weld
is activate. Welding sequences other than
Weld must be set prior to initiating the arc.
• In the weld sequence display mode the Sequence push button LED is Off. When the
Sequence push button is pressed, the Sequence push button flashes and the Start
LEDs flash. In this condition, the unit is in the
Start sequence display mode, and Start sequence parameters are shown in the displays.
• When the Sequence push button is pressed
a second time, the Crater sequence LED
flashes. The Sequence push button LED remains flashing. In this condition, the unit is
in the Crater sequence display mode, and
Crater sequence parameters are shown in
the displays.
• When the Sequence push button is pressed
a third time, the Preflow/Postflow sequence
LED flashes. The Sequence push button
LED remains flashing. In the Preflow display
mode the upper display shows the preflow
time and the lower display indicates the abbreviation PRE, to inform the operator that
preflow time is displayed. If the upper display push button is pressed, the Adjust control can be used to adjust preflow.
If the lower display push button is pressed, the
Adjust control can be used to select between
preflow PRE and postflow POST. When
POST is selected, the upper display can be
used to specify postflow time.
• When the Sequence push button is pressed
a fourth time, the unit returns to the welding
sequence display mode.
OM-1500-7 Page 23
6-12. Auxiliary Menus
1
2
3
4
5
6
7
8
9
4
5
1
7
2
Program Display
Program Push Button
Sequence Push Button
Upper Display
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
Setup Push Button
6
9
3
8
6-12 Auxiliary Menus (Continued)
Reset To Factory Settings
A reset menu is displayed if the following four
push buttons are pressed simultaneously:
Program, Sequence, upper display, and Setup. The upper display indicates “WIPE” . The
lower display indicates “OFF”. The lower push
button is active indicating that the Adjust control can be used to change the unit to “WIPE
ON”. When “WIPE ON” is set, if the original
four push buttons are simultaneously pressed
a second time, the unit will reset all settings to
factory default except the arc time and arc
cycle counts. If a reset is not desired, set the
display to “WIPE OFF” and simultaneously
press the Program, Sequence, upper display,
and Setup push buttons to exit the reset menu.
Auxiliary Menu
• An auxiliary menu is provided if both the Sequence and Setup push buttons are pressed
simultaneously. The Setup push button and
sequence push button LEDS flash when the
auxiliary menu is displayed.
Pushing the Setup push button will step
through the menu. Pushing the sequence
push button will step through the menu in reverse.
. The auxiliary menu may be exited at any
time by pressing both the Sequence push
button and the Setup push buttons simultaneously.
V-Min And V-Max
• If the Setup push button is pressed, the unit
allows the setting of the manual override
power source min and max voltage preset
range. The minimum voltage is displayed in
the upper display and the lower display indi-
OM-1500-7 Page 24
cates “VMIN”. When the Setup push button
is pressed the unit displays the maximum
voltage setting of the welding power source.
The maximum voltage is displayed in the upper display and the lower display indicates
“VMAX”.
In both cases, the Adjust control is used to
specify the minimum and maximum voltage
settings of the welding power source. The settings correspond to arc voltage obtained at
minimum command and arc voltage obtained
at maximum command.
This method of setting “VMIN” and “VMAX”
may be used if the power source being used
is not listed in the Power Source Selection
Menu.
. If a default power source has already been
selected with the Power Source Selection
menu, setting “VMIN” and “VMAX” will
override the default power source settings.
. The power source selection menu must
be set to “OFF” when overriding the default “VMIN” or “VMAX” settings.
Arc time is indicated by the Program display
showing “HR”. Arc time is shown in the lower
display.
Cycles
• If the Setup push button is pressed, the unit
displays the number of cycles.
Arc cycles are indicated by the Program display showing “CL”. The arc cycle count is
shown in the lower display.
Run-In
• If the Setup button is pressed, the unit allows
setting the run-in modes. The run-in modes
are program specific. Each program may be
set to its own run-in mode.
The upper display indicates “RUNI”. The
lower display indicates “AUTO”, meaning the
factory set automatic run-in speed is selected.
Pressing the lower display button allows a
manual setting the run-in wire speed. Speed
may be adjusted from 10% to 100% of weld
wire speed.
Pressing the lower display button allows disabling of the run-in feature. When the lower
display indicates “OFF” run-in is disabled.
Power Source Selection Menu
Burnback
• If the Setup push button is pressed, the unit
allows the Power Source Selection menu to
be disabled or enabled.
• If the Setup push button is pressed, the unit
allows burnback time to be set.
The upper display shows “PSS”. Lower display shows “On” or “Off”. The Adjust Control is
used to select either “On” or “Off”.
Arc Time
• If the Setup push button is pressed, the unit
displays arc time in hours.
Burnback time and voltage can be specified
when the lower display indicates “BURN” and
the upper display indicates the burnback time
or voltage. The Adjust control is used to set the
desired burnback time or voltage. Burnback
settings, like run-in settings, are program specific. The active program is displayed in the
Program display and can be adjusted (see
Section 7-1).
6-12 Auxiliary Menus (Continued)
Trigger Hold Setup
• If the Setup push button is pressed, the unit
allows trigger hold delay time to be set.
Trigger hold delay time is indicated by ”HOLD”
in the lower display and the hold delay time in
the upper display. The adjust control can be
used to specify a new delay time for trigger
hold. Trigger hold delay time is the minimum
amount of time the trigger must be held for trigger hold to work when the trigger is released
(the trigger hold function must be on). For example, if a trigger hold delay time of 2.0 seconds is defined, the operator must hold the
trigger for at least 2 seconds before releasing
it in order for the trigger hold function to work.
Once the trigger hold function is in effect, the
wire feeder will stay On until the trigger is
pressed and released again.
• There is an additional function built in called
”maximum trigger hold time” which is the
maximum length of time the trigger can be
held and the trigger hold function still work
when the trigger is released (the trigger hold
function must be on). The maximum trigger
hold time is set at 4.0 seconds after the trigger hold delay time. For example, if a trigger
hold delay time of 2.0 seconds is defined,
and the operator held the trigger in for more
than 6.0 seconds, the trigger hold function
would not be in effect and the wire feeder
would stop when the trigger is released.
operator to select programs during preflow by
clicking the trigger (pulling and releasing the
trigger in a maximum of 0.2 seconds). The
feeder will switch between any programs that
have a minimum of 0.2 seconds of preflow
time set in the weld sequence. Any combination of programs may be used. Trigger Program Select cannot be used while welding or
with Dual Schedule.
(Example: If programs 1 and 3 have a minimum of 0.2 seconds of preflow time, clicking
the trigger will toggle between programs 1 and
3).
Trigger Dual Schedule Select (DUAL) allows
the operator to switch between paired schedules (programs 1−2, 3−4, 5−6, or 7−8) with the
gun trigger, but only while welding. This feature cannot be used with Trigger Hold or Dual
Schedule. To end the weld, the trigger must be
released for 0.4 seconds.
(Example: when welding with this feature enabled in program 1, if you release, re-trigger,
and hold again within <0.4 seconds, the active
program will switch to program 2. If the previous sequence is repeated the active program will switch back to program 1. This cycle
can be repeated for the entire weld).
Process Select
the upper display and “OPT1” in the lower display.
OPT2
• If the Setup push button is pressed, the unit
allows OPT2 to be disabled or enabled.
The upper display shows “OPT2”. Lower display shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
“OPT2” is a second input that may be used
with an external device, such as a gas flow
switch, to end the weld sequence. The gas
flow switch may be used to stop the weld sequence if shielding gas flow to the gun is interrupted. A closed set of contacts between pins
1 and 2 of RC24 on Interface Board (PC20)
will allow feeder to operate normally. Opening
the contacts will stop the weld sequence and
display “ERR” in the upper display and
“OPT2” in the lower display.
Display Hold
Display hold indicated by ”DISP” in the upper
display is set to “OFF” or “HOLD” in the lower
display. When ”HOLD” is selected, the unit will
hold the last weld information for 5 seconds
following weld termination. If any front panel
push button is pressed, or if the Adjust control
is activated, the display hold feature is terminated.
• When the Setup push button is pressed
again, the menu repeats to the first menu
selection of run-in wire speed selection.
Process selection indicated by ”PROS” in the
upper display is set to either ”VOLT” or ”TRIM”
in the lower display. Each program can be selected be be a MIG program indicated by
”VOLT” or a pulsing program indicated by
”TRIM”.
Range Locks
Wire Feed Speed Units
• When the Setup button is pressed again, the
menu repeats.
Range locks are indicated by “LOCK” in the
upper display for wire speed or “LOCK” in the
lower display for voltage range. In a MIG program, the voltage range lock ranges from 0 to
10 volts. In a pulse program, the trim range
lock ranges from 0 to 100. The wire feed
speed range lock ranges from 0 to 250 ipm.
Locks are program dependent and wire speed
is independent from voltage or trim.
Wire feed speed setting indicated by “WFS” in
the upper display is set to “IPM” inches−per−
minute or ”MPM” meters−per−minute. This
setting is independent of the program selected.
Code
Trigger Program Select
The upper display shows “OPT1”. Lower display shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
• If the Setup push button is pressed, the unit
allows Trigger Program Select or Trigger
Dual Schedule to be enabled or disabled.
The upper display shows “TSEL”. Lower display shows “OFF” or “PROG” or “DUAL”. The
Adjust Control is used to select “OFF” or
“PROG” or “DUAL”.
Trigger Program Select (PROG) allows the
OPT1
• If the Setup push button is pressed, the unit
allows OPT1 to be disabled or enabled.
“OPT1” is used by the Water Flow Shutdown
Option to stop the weld sequence if water flow
to a water cooled gun is interrupted. A closed
set of contacts between pins 1 and 2 of RC26
on Interface Board (PC20) will allow feeder to
operate normally. Opening the contacts will
stop the weld sequence and display “ERR” in
Software Revision Level
• If the Setup push button is pressed, the unit
displays the software version being used by
the interface PCB (PC20).
Upon leaving the auxiliary menu, the user is
asked if a password code indicated by
“CODE” in the top display should be activated.
By default the code is off, indicated by “OFF”
in the lower display. The user may enter a numerical password between 0 and 999 by turning the Adjust control. When the user re−enters the auxiliary menu, the password code
must be selected to gain access to the auxiliary menu. A failed attempt return the user to the
weld screen and a counter is incremented. A
counter in the program display shows the
number of incorrect attempts. The user has
five attempts to enter the correct password
code before being locked out of the auxiliary
menu, indicated by “LOCK” in the lower display . The power may be cycled to continue
welding but the user will remained locked out
of the auxiliary menu.
OM-1500-7 Page 25
SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence Push Button see
Section 6-12.
Sequence
If time is set to zero in Weld
sequence, welding continues until
gun trigger is released.
Parameters
IPM
Seconds
Volts
1. Preflow
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
0-9.9
2. Run-In
X
3. Start
X
X
0.00-5.00
4. Weld
X
X
0-100.0
5. Crater
X
X
0-5.00
6. Burnback
X
0-0.25
7. Postflow
0-9.9
X = Setting available.
Weld Time
Crater
Time
Preflow
Time
Start
Time
Burnback
Time
Postflow
Time
Time
Preflow
Run-In Start
Weld
Crater
Trigger
Pressed
Burnback
Postflow Sequence
End
Trigger
Released
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS
8-1. Optional Dual Schedule Switch Diagrams
1
1
DSS-9
2
1
2
DSS-8
3
2
1
2
TR
B
A
1
2
3
A
4
B
OM-1500-7 Page 26
4
Maint 2P (Maintained-Contact
2-Pole Switch)
Maint 1P (Maintained-Contact
1-Pole Switch)
. Will not function with trigger
hold and dual schedule. A
DSS-9 is recommended for
this application.
8-2. Diagnostics
1
2
2
3
3
LED3 On Right Side Motor
Control Board PC1
LED3 On Left Side Motor
Control Board PC101
LED4 On Dual Board PC70
. There
is a two-position DIP
switch S1 located on motor control boards PC1 and PC101.
These switches are factory-set
in the off position and must remain in that position for the unit to
operate correctly.
1
805 407-A
Left Side Motor Control Board PC101
. Note: The error messages
are shown on the upper
and lower displays to indicate specific errors. Explanations are in the text
below:
ERR
ERR
ERR
ERR
COM1
TRG1
TCH1
MTR1
Indicates a communication error.
Indicates a trigger
error.
Indicates a
tachometer error.
Indicates a motor
error.
Right Side Motor Control Board PC1
ERR
ERR
ERR
ERR
COM2
TRG2
TCH2
MTR2
Indicates a communication error.
Indicates a trigger
error.
Indicates a
tachometer error.
Indicates a motor
error.
Dual Board PC70
ERR
COM3
LED3-Related Error Indications
Error conditions are indicated by LED3 on
PC1, PC101, and LED4 on PC70. To view
LED3, 4 turn Off unit, remove wrapper, and
turn unit On.
The LED blinks in a 2.5 second cycle. The
number of blinks in this period indicates the
type of error.
The priority of the errors is related to the number of blinks indicating the error. The more
blinks, the more severe the error (motor error
is top priority). A higher priority error overrides
a lower one (if a motor error and a communication error existed, the light would blink four
times for the motor error).
Since blink On time and blink Off time are
equal in a four-blink cycle, the four−blink sequence appears as a constant blink.
Indicates a
communication
error.
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach Error
4 blinks = Motor Error
• The communication error occurs 2.5 seconds after a loss of communication between
the motor and the Front Panel board or Dual
board. The user may continue to weld with
this error.
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The user may
continue to weld with this error. The motor
speed is regulated through the monitoring of
voltage and current.
• The motor error indicates that the motor
has been drawing too much current for too
long.
• The trigger error occurs if the user has the
trigger held for more than two minutes without striking an arc (providing current override is not enabled), or if the user holds the
trigger past the postflow phase in a timed
weld. This error also occurs if the trigger is
held when the feeder is powered up. The error may be cleared by releasing the trigger.
OM-1500-7 Page 27
8-3. Diagnostics For User Defined Options
1
2
Front Panel
Front Panel Board PC20
User Defined Shutdown Error
Messages (Additional hardware
required for these to be functional)
1
If OPT1 and/or OPT2 are enabled
without additional hardware setup,
the following error messages will be
displayed on the front panel meters.
OPT1 and/or OPT2 must be disabled.
. Refer to Section 6-12 for cor-
2
ERR
ERR
OPT1
OPT2
rect setup procedures.
Indicates a User Defined Option Error
803 071
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Routine Maintenance
!
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
3 Months
Clean and
tighten
weld
terminals.
Replace
unreadable
labels.
Replace
cracked
parts.
Check
14-pin cord.
Repair or
replace
cracked
weld
cable.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
monthly.
OM-1500-7 Page 28
Or
Clean
drive rolls.
9-2. Troubleshooting
!
Disconnect power before troubleshooting.
Trouble
Remedy
Wire feeds, shielding gas flows, but elec- Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see
trode wire is not energized.
Sections 5-4 and 5-5).
Wire feeder is on, meter(s) do not light Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
Electrode wire feeding stops or feeds er- Check gun trigger connection. See gun Owner’s Manual.
ratically during welding.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 5-8).
Change to correct size drive roll (see Table 11-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire does not feed until trigger is pulled, Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
but continues to feed after trigger is released, and trigger hold is not on.
Gas valve in feeder is rattling loudly Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
along with possible erratic or slow wire
feed speed.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
OM-1500-7 Page 29
SECTION 10 − ELECTRICAL DIAGRAM
OM-1500-7 Page 30
236 292-B
OM-1500-7 Page 31
SECTION 11 − PARTS LIST
. Hardware is common and
not available unless listed.
6
7
8
9
10
5
11
12
11
10
9
13
14
16
4
17
Fig.11−3
18
3
15
2
19
1
20
22
21
Fig.11−2
803 052-A
Figure 11-1. Main Assembly
OM-1500-7 Page 32
Item
No.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 159 647 . . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . 159 646 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . 159 360 . . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . 201 762 . . Drive Assy, Wire S/L 4 Roll W/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . 208 831 . . Drive Assy, Wire S/L 4 Roll Lo-Speed W/Tach . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . 201 763 . . Drive Assy,Wire S/L 4 Roll Hi−Speed W/Tach . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . 143 160 . . Hub+Spindle Assy, (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . . 058 427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . 180 571 . . . . Shaft, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . 010 233 . . . . Spring, Cprsn .970 Od X .120 Wire X 1.250Pld . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . . 057 971 . . . . Washer, Flat Stl Keyed 1.500Dia X .125Thk . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . . 010 191 . . . . Washer, Fbr .656 Id X 1.500 Od X .125Thk . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . 058 628 . . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . 058 428 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . 071 730 . . . . Tubing, STL .875 Od X 12Ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . 135 205 . . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . 141 411 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . 204 484 . . Extension, Dual Clamp L.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . 208 338 . . Extension, Dual Clamp R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . 156 243 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . 145 639 . . Strip, Buna−n .062 X 3.000 X 4.000 Compressed Sht . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . 139 226 . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . 134 306 . . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box (Refer to Figure 11-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . 201 768 . . Drive Assy, Wire R 4 Roll W/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . 208 830 . . Drive Assy, Wire R 4 Roll Lo-Speed W/Tach . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . 201 769 . . Drive Assy,Wire R 4 Roll Hi−Speed W/Tach . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 164 059 . . Hose, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
8
1
1
1
2
1
1
1
2
2
2
1
2
1
1
1
1
2
2
1
4
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1500-7 Page 33
. Hardware is common and
not available unless listed.
29
9
8
1
11
7
10
12
13
14
2
15
28
4
3
16
9
6
27
26
5
17
19
25
8
24
20
18
21
22
23
805 428-A
Figure 11-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box (Figure 11-1 Item 21)
... 1 ...............
.....................
... 2 ...............
... 3 ...............
. . . 4 . . . . PC21 . . . . .
. . . 5 . . . . PC20 . . . . .
. . . 6 . . . . . S1 . . . . . .
. . . 7 . . . . PC70 . . . . .
. . . 8 . . PC1,101 . . .
... 9 ...............
. . . 10 . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . .
. . . 15 . . . PLG12 . . . .
. . . . . . . . . PLG52 . . . .
. . . . . . . . . PLG74 . . . .
. . . 16 . . . . . . . . . . . . . . .
. . . 17 . . GS1,101 . . .
. . . 18 . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
OM-1500-7 Page 34
204 722
238 487
206 764
204 762
238 273
235 331
111 997
237 752
238 469
030 170
000 527
200 196
139 041
163 519
079 739
141 162
174 823
115 093
605 227
228 035
010 494
134 201
235 217
. . Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Label, Warning General Precautionary (CE/Domestic) . . . . . . . . . . . . . . 1
. . Panel, Circuit Card Assy (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Overlay, Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Card Assy,Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Circuit Card Assy, Display/Micro W/Program (CE) . . . . . . . . . . . . . . . . 1
. . Switch, Rocker Spst 10A 250VAC On-Off Visi Red Rock . . . . . . . . . . . . 1
. . Circuit Card Assy, Dual W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Circuit Card Assy, Motor Control W/Program . . . . . . . . . . . . . . . . . . . . . . 2
. . Bushing,Snap−in Nyl .750 Id X 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 3
. . Blank, Snap−in Nyl .875 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Power 11.5Ft 8/C 2-14Ga 6-18Ga (Consisting Of) . . . . . . . . . . . . 1
. . . . Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Cable, Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Ft (3.5 m)
. . . . Conn, Circ Cpc Clamp Str Rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Nut, 750−14 Knurled1.68Dia .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Valve, 34VDC 1Way .750−14 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . 2
. . Bushing, Snap−in Nyl 1.375 Id X 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . . 2
. . Stand−Off Support, PC Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . 17
. . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box (Continued)
...
...
...
...
...
...
...
...
...
...
...
21
22
22
23
24
25
26
26
27
28
29
...............
...............
...............
. . . S2,102 . . . .
. . . . S100 . . . . .
...............
...............
...............
...............
...............
...............
206 765
206 771
206 515
200 295
201 641
213 134
207 745
207 744
237 667
211 989
232 880
..
..
..
..
..
..
..
..
..
..
..
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Lower (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Rocker Spdt 15A 12V (On)−Off−(On) . . . . . . . . . . . . . . . . . . . . . .
Switch, Rocker Spdt 15A 12V (On)−Off−(On) W/leds . . . . . . . . . . . . . . .
Knob, Encoder 1.670 Dia x .250 Id Push On W/Spring . . . . . . . . . . . . . .
Nameplate, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Upper (CE Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assembly, Trigger Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy,14 Pin Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
2
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Dia.
Part
Mkgs.
No.
Description
Quantity
Harness Connectors/Receptacles
. . . . . . . . PLG6,106 . . .
. . . . . . . PLG10,110 . .
. . . . . . . . . PLG72 . . . .
. . . . . . . . PLG4,104 . . .
. . . . PLG11, 21,71,111
. . PLG1,77,78,79,101
. . . . . PLG3,75,76,103
. . . . . . . . . PLG51 . . . .
. . . . . PLG7,27,67,107
. . . . . . . . . PLG73 . . . .
. . . . . . . . PLG17,70 . . .
. . . . . . . . PLG117 . . .
115 094
130 203
115 092
136 810
131 055
202 592
115 093
174 824
115 091
148 439
158 719
165 404
..
..
..
..
..
..
..
..
..
..
..
..
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
OM-1500-7 Page 35
. Hardware is common and
13
not available unless listed.
19
11
14
15
16
See Table 11-1 For
Drive Roll & Wire Guide Kits
1
2
3
4
5
17
7
6
18
9
8
19
12
10
20
11
22
21
37
34
36
35
27
33
23
24
25
26
28
32
31
30
29
3
4
5
6
2
1
803 790-A
Figure 11-3. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4)
. . . 1 . . . . . . . . . . . . . . . 010 668
. . . 2 . . . . . . . . . . . . . . . 172 075
. . . 3 . . . . . . . . . . . . . . . 149 962
. . . 4 . . . . . . . . . . . . . . . 149 486
. . . 5 . . . . . . . . . . . . . . . 132 750
. . . 6 . . . . . . . . . . . . . . . 150 520
. . . 7 . . . . . . . . . . . . . . . 133 493
. . . 8 . . . . . . . . . . . . . . . 133 350
. . . 9 . . M1,101 . . . . . 201 230
. . . 9 . . M1,101 . . . . . 201 231
. . . 9 . . M1,101 . . . . . 207 892
. . . . . . . . . . . . . . . . . . . . . 153 491
. . . . . . . . . . . . . . . . . . . . . 153 492
. . . . . . . . . . . . . . . . . . . . *153 493
. . . . . . . . . . . . . . . . . . . . . 184 136
. . . 10 . . . . . . . . . . . . . . . 155 098
. . . . . . . . . . . . . . . . . . . . . 153 550
. . . . . . . . . . . . . . . . . . . . . 155 099
. . . . . . . . . . . . . . . . . . . . . 155 100
. . . . . . . . . . . . . . . . . . . . . 154 031
. . . . . . . . . . . . . . . . . . . . . 133 493
. . . . . . . . . . . . . . . . . . . . . 203 642
. . . . . . . . . . . . . . . . . . . . . 203 631
. . . 11 . . . . . . . . . . . . . . . 203 641
. . . 12 . . . . . . . . . . . . . . . 182 415
. . . 13 . . . . . . . . . . . . . . . 203 640
OM-1500-7 Page 36
. . Screw, Cap Stl Sch .250-20 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Carrier, Drive Roll W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Flat Stl .257 Id X .619 Od X .105 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ring, Retaining Ext .250 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/8HP 24VDC Standard Speed . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/8HP 24VDC High Speed (Optional) . . . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/8HP 24VDC Low Speed (Optional) . . . . . . . . . . . . . . . . . . .
. . . . Kit, Brush Replacement (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Cap, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Brush, Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Brush Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Cover Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cover, Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Gasket, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Screw, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Rtng Ext .250 Shaft Grv X .025Thk . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pressure Arm, R & Vert L 4 Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . .
. . Pressure Arm, S/L & Vert S/R 4 Roll (Consisting Of) . . . . . . . . . . . . . . . . .
. . . . Washer, Flat Indicator Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, W/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
2
2
2
2
1
1
1
1
1
2
2
1
1
1
1
5
2
1
1
1
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Drive Assembly, Wire (continued)
. . . 14 . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
. . . 21 . PC51,151 . . .
. . . . . . . . . PLG5 . . . . .
.....................
. . . 22 . . . . . . . . . . . . . . .
.....................
. . . 23 . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . .
.....................
. . . 34 . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . .
182 156
182 155
132 746
203 633
203 632
133 739
203 637
237 048
131 204
604 311
132 611
603 115
167 387
168 825
133 308
134 834
149 959
179 265
179 264
108 940
604 538
151 437
151 290
179 277
178 937
601 872
602 213
602 243
601 966
. . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Flat Buna .375 Id X .625 Od X .062Thk . . . . . . . . . . . . . . . . . . . 2
. . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Circuit Card, Digital Tach (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Grommet, Rbr .250 Id X .375Mtg Hole .062 Groove . . . . . . . . . . . . . . . . 1
. . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Weather Stripping, Adh .125 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ring, Retaining Ext .375 Shaft X .025Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Sae .187 Id X .410 Od (Order By Ft) . . . . . . . . . . . . . . . . . . . 2Ft (0.6 m)
. . Fitting, Brs Barbed M 3/16tbg X .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, Gun/Feeder LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, Gun/Feeder RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Hexhd .250-20 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Washer, Flat Stl Sae .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Knob, Plstc T 1.125 Lg X .312-18 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Mach Stl Hexwhd 10-32 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Cover, Drive Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Hexhd .375-16 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1500-7 Page 37
Table 11-1. Drive Roll And Wire Guide Kits
OM-1500-7 Page 38
Inlet Guide
221030
221030
221030
229919
229919
Wire Sizes
.023 to .040 in. (0.6 to 1.0mm)
.045 to .052 in. (1.1 to 1.4mm)
1/16 to 5/64 in. (1.6 to 2mm)
3/32 to 7/64 in. (2.4 to 2.8mm)
1/8 in. (3.2mm)
Wire Guides
*Accommodates .045 and .047 (3/64 in) wire
**Requires a low *speed wire feeder
149522
149521
149520
149519
149518
Intermediate Guide
151042
151043**
151076**
151075
151074
151073
151072
151071
151070
”U” COGGED FOR
EXTREMELY SOFT
WIRE OR SOFT*
SHELLED CORED
WIRES
1/16 in. (1.6mm)
.047 in. (1.2mm)
.035 in. (0.9mm)
Wire Size
221912
221912
221912
Inlet Guide
Nylon Wire Guides for Feeding Aluminum Wire
151060**
151059
151058
1/8 in. (3.2 mm)
151055
7/64 in. (2.8 mm)
151039
151054
151053
151041
151029
1/16 in. (1.6 mm)
151038
151037*
3/32 in. (2.4 mm)
151028
.052 in. (1.3/1.4 mm)
151057
151027
.045 in. (1.1/1.2 mm)
151056
161190
.040 in. (1.0 mm)
151052
151040
151026
.035 in. (0.9 mm)
”V” KNURLED FOR
HARD*SHELLED
CORED WIRES
5/64 in. (2.0 mm)
151025
.030 in. (0.8 mm)
”U” GROOVE FOR
SOFT*SHELLED
CORED WIRES
.068/.072 in. (1.8 mm)
151024
.023/.025 in. (0.6 mm)
WIRE SIZE
”V” GROOVE FOR
HARD WIRE
205937
205936
242417
Intermediate Guide
243235
243234*
243233
”U” GROOVE FOR
ALUMINUM WIRES
CONTAINS NYLON
WIRE GUIDES
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