Miller AUTO-AXCESS 300 DI CE User manual

OM-250 878H
2014−05
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
Auto-Axcess 300 DI

CE
Visit our website at
www.MillerWelds.com/ams
File: Advanced Manufacturing Systems
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. 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. Additional Safety Symbols and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Devicenet Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. E-Stop Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Connecting 3−Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Robot Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Robot Auto-Calibration Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Error Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Process Control Module PC4 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Diagnostic LEDs On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Diagnostic LEDs On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8. User Interface Module PC7 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9. Diagnostic LEDs On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-10. Network And Module Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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52
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
Auto­Axcess 300 Digital CE
Auto­Axcess 300 Digital CE w/Rmd
Auto­Axcess 300 CE DeviceNet w/Low Inertia Motor
Auto­Axcess 300 CE Digital w/Insight Core
907349002
907349003
907349004
907349005
Council Directives:
 2006/95/EC Low Voltage
 2004/108/EC Electromagnetic Compatibility
 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
 IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
 IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
June 6, 2014
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
250907D
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
D
D
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D
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disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
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-250 878 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. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
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 containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (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-250 878 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing 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.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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 compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
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.
Compressed 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 compressed 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. Do
not stand in front of or behind the regulator when opening the 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.
OVERUSE can cause OVERHEATING
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.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
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
D Sparks can cause fires — keep flammables away.
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.
D
D
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.
MOVING PARTS can injure.
ARC WELDING can cause interference.
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.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
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-250 878 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.)
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,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased 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).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, 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, 14501 George Carter Way, Suite
103, 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).
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). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct 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-250 878 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_2013−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
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
D
D
D
D
D
D
D
D
D
D
D
D
D
D
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales 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 et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
OM-250 878 Page 5
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
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.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
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.
OM-250 878 Page 6
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 un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
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.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(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 un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
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.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
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 comprimé 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.
LE BRUIT peut endommager l’ouïe.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé 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 comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
spécifique; les maintenir ainsi que les éléments associés en bon
état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
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.
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.
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.
OM-250 878 Page 7
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
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.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
D
D
D
D
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer
des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
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.
OM-250 878 Page 8
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.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
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.
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)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased 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).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, 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, 14501 George Carter Way, Suite
103, 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).
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).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit 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: Limiter par exemple tout accès aux passants ou
procéder à une évaluation des risques individuels pour les soudeurs.
Tous les soudeurs doivent appliquer les procédures suivantes pour
minimiser l’exposition aux CEM provenant 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.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
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.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-250 878 Page 9
OM-250 878 Page 10
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols and Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
OM-250 878 Page 11
Do not remove or paint over (cover) the label.
Safe20 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not use one eye bolt to lift or support unit.
Safe31 2012−05
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.
Safe37 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
V
V
>5min
= < 60
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
V
Safe43 2012−05
Always lift and support unit using both eye bolts. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
OM-250 878 Page 12
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
Direct Current
(DC)
Alternating
Current (AC)
Output
Circuit Breaker
Remote
On
Off
Positive
Negative
Voltage Input
Arc Force
Constant Voltage
Inductance
Protective Earth
(Ground)
Gas Metal Arc
Welding (GMAW)
Three Phase Static
Frequency ConverterTransformerRectifier
Increase
U0
Rated No Load
Voltage (Average)
Hz
Hertz
Line Connection
U1
IP
Primary Voltage
Degree Of
Protection
U2
I2
Pulsed
I1max
V
Amperage
Rated Maximum
Supply Current
Conventional
Load Voltage
Rated Welding
Current
Single Phase
I1eff
Maximum Effective
Supply Current
S
X
%
Voltage
Duty Cycle
Percent
Three Phase
Suitable for Some
Hazardous
Locations
Notes
OM-250 878 Page 13
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back . 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.
4-2. Unit Specifications
Input
Power
Three
Phase
Rated
Welding
Output
225 A @
25.3 V DC,
100%
Duty
Cycle
Voltage
Range
10-44
Wire Feed
Speed
Range**
Wire
Diameter
Range
Max
Open
Circuit Voltage
DC
Standard:
1.3-35.6
mpm
(50-1400
ipm)
0.8-1.6 mm
(.035-.062
in.)
75
Amperes Input At Rated
Load Output 60 Hz,
Single-Phase/Three-Phase
380V
400V
10.9
(0-1A*)
10.3
(0-1A*)
Input
kVA
Input
KW
7.1
(0.2*)
6.8
(0.04*)
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.
4-3. Dimensions And Weight
Hole Layout Dimensions
A
A
434 mm (17-3/32 in.)
B
441 mm (17-3/8 in.)
C
485 mm (19-3/32 in.)
D
409 mm (16-3/32 in.)
E
13 mm (1/2 in.)
552 mm
(21-3/4 in.)
C
584 mm
(23 in.)
B
Weight
51 kg (112 lb) Net
61 kg (134 lb) Ship
OM-250 878 Page 14
E
434 mm
(17-3/32 in.)
D
Ref. 803 675-A
4-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
500
WELD AMPERES
400
3 PHASE
OPERATION
300
250
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
200
150
100
10
15
20
25 30
40
50 60 70 80 90 100
230 226-B
% DUTY CYCLE
100% Duty Cycle At 225 Amperes
60% Duty Cycle At 300 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 178 651
4-5. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
CV MODE
80
70
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
VOLTAGE
60
50
40
30
20
10
0
0
100
200
300
AMPERAGE
400
500
600
va_curve1 4/95
OM-250 878 Page 15
4-6. Environmental Specifications
A. IP Rating
IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
B. 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
C. 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 can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 4,371,835 at the interface
point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 4,371,835.
ce-emc 1 2011-09
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-250 878 Page 16
SECTION 5 − INSTALLATION
. Appearance of actual unit may vary from unit shown in manual.
5-1. Selecting A Location
!
Tipping
Movement
2
Do not move or operate
unit where it could tip.
OR
1
Location
!
!
3
Special installation may be required
where gasoline or volatile liquids
are present − see NEC Article 511 or
CEC Section 20.
Do not stack units. Beware of
tipping.
1 Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side
of unit.
2 Hand Cart
460 mm
(18 in.)
Use cart or similar device to move
unit.
3 Line Disconnect Device
Locate unit near correct input
power supply.
460 mm
(18 in.)
Ref: loc_2 3/96 -Ref. 803 675-A
5-2. Connection Diagram
. The proper interface kit must
be installed in the welding
power source/interface unit to
allow it to be connected to the
robot.
2
5
3
4
1
6
12
10
7
13
8
1 Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 E-Stop Cable
7 Gas And Motor Control Cable
8 Welding Power
Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
11 Voltage Sensing Lead
Recommended for Accu-pulse and
RMD (optional).
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
11
12 Positive (+) Weld Cable
13 Devicenet Robot/Welder
Control Cable
9
Ref. 803 675-A / Ref. 801 915-A
OM-250 878 Page 17
5-3. Rear Panel Receptacles And Supplementary Protectors
1 115 V 10 A AC Receptacle RC2
4
1
6
5
2
Receptacle
supplies
60
Hz
single-phase power. Maximum output
from RC2 is limited by supplementary
protector CB1 to 10 amps.
2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects 115 volt receptacle RC2
from overload. If CB1 opens, RC2 does
not work.
3
CB2 protects the wirefeed motor from
overload. If CB2 opens, the wirefeeder
does not work.
. Press
button to reset breaker. If
breaker continue to open, contact a
Factory Authorized Service Agent.
4 Wirefeed/Gas Receptacle RC8
7
Use receptacle to connect gas and
motor control cable to power source
(see Sections 5-2 and 8 for additional
information).
5 Peripheral Receptacle RC25
. RC25 is not used with Devicenet.
6 E-Stop Receptacle RC
A short across the two sockets allows
unit to weld.
7 Devicenet Receptacle RC
Network control cable connection for robot/welder communication.
Ref. 804 574-A
5-4. Connecting To Weld Terminals
. If using an electrode negative (straight polarity) process,
the volt sense lead must be disconnected from the work.
3
6
Do not place
anything
between weld
cable terminal
and weld copper
bar.
4
5
Correct Installation
1
Tools Needed:
Incorrect Installation
2
Ref. 803 675-A / 803 778-A
19 mm (3/4 in.)
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Determine total cable length in weld circuit
(both positive and negative cables
combined) and maximum welding
amperes. See Section 5-5 to select proper
cable size.
OM-250 878 Page 18
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal
Connect positive weld cable to Positive (+)
weld terminal and negative (−) cable to
Negative weld terminal.
3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld output terminal and secure with nut so
that weld cable terminal is tight against
copper bar. Do not place anything
between weld cable terminal and copper
bar. Make sure that the surfaces of the
weld cable terminal and copper bar are
clean.
5-5. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or repaired
cables.
30 m (100 ft) or Less
)
* This
Negative
*
Ref. 803 677-A
60 m
(200 ft)
70 m
(250 ft)
90 m
(300 ft)
105 m
(350 ft)
120 m
(400 ft)
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
250
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x70
(2x2/0)
300
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x95
(2x3/0)
350
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x95
(2x3/0)
2x120
(2x4/0)
400
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
2x120
(2x4/0)
500
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
3x95
(3x3/0)
3x95
(3x3/0)
600
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
3x95
(3x3/0)
3x120
(3x4/0)
3x120
(3x4/0)
700
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
3x95
(3x3/0)
3x120
(3x4/0)
3x120
(3x4/0)
4x120
(4x4/0)
800
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
3x120
(3x4/0)
3x120
(3x4/0)
4x120
(4x4/0)
4x120
(4x4/0)
Welding
Amperes
Positive
45 m
(150 ft)
10 − 100% Duty Cycle
mm2 (AWG)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
Milan Ref. S-0007-K 2013−09
OM-250 878 Page 19
5-6. Devicenet Receptacle Functions
Socket
C
Socket Information
A
Chassis ground.
B
+24 volts DC; available current is 1 ampere.
C
+24 volts DC common.
D
CAN H.
E
CAN L.
D
B
A
E
Ref. 804 574-A
5-7. Motor Control Receptacle Functions
G
J
K
Socket
C
A
F
E
H
D
B
Ref. 804 574--A
Socket Information
A
Not used.
B
Motor negative (−).
C
Tach A, 0 volts = low and 3.5 volts = high.
D
Motor positive (+).
E
Tach common.
F
Gas valve, +40 volts DC when valve is on with respect to
socket K.
G
Electrode sense.
H
Tach +5 volts DC with respect to socket E.
J
Tach B, 0 volts = low and 3.5 volts = high.
K
Gas valve.
5-8. E-Stop Receptacle Functions
A
B
Ref. 804 574-A
OM-250 878 Page 20
Socket
Socket Information
A
A short to socket B allows unit to weld.
B
A short to socket A allows unit to weld.
5-9. Electrical Service Guide
Elec Serv 2014−01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
. Actual input voltage should not exceed  10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
50/60 Hz Three
Phase
380
400
10.9
10.3
Time-Delay Fuses 2
10
10
Normal Operating Fuses 3
15
15
14
14
62
(204)
69
(226)
14
14
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In
Amperes1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Meters (Feet)
Min Grounding Conductor Size In AWG 4
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
5-10. Remote Program Select
. Remote Program Select is factory set to “On”. WaveWriter software is required to turn this function “Off”.
When Remote Program Select is On, a robot pendant may be used to select programs. When Off, program selection must be done from the robot
pendant.
5-11. Remote Program Setting
When Remote Program Select is “On”, program selection will be determined by remote input through Devicenet once a weld is initiated. Prior to welding, program selection can be done in a normal manner from the welding power source front control panel.
5-12. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle. Turning on touch sensor causes a DC voltage to be
present on the welding wire. When welding wire touches the weldment, the voltage sensing circuit closes, and a digital output signal is sent to the robot
control indicating weldment detection. Touch sensor DC voltage on the welding wire is 80 volts DC. As soon as touch sensor turns on, WIRE LIVE
appears on the front panel display.
OM-250 878 Page 21
5-13. Connecting 3−Phase Input Power
3
= GND/PE Earth Ground
8
10
7
L1
4
6
L2
L3
9
1
6
5
Route input conductors to
filter board.
Route ground conductor
through tubing and current
transducer to ground terminal.
4
3
2
Tools Needed:
5/16 in.
OM-250 878 Page 22
Input5 2012−05 −Ref. 803 766-C / 804 650-A / Ref. 803 855-A
5-13. Connecting 3-Phase Input Power (Continued)
!
!
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 9-3 before
proceeding.
575 VAC without removing cover to relink the
power source.
5 Welding Power Source Line Terminals
6 Input Conductors L1, L2, L3
See rating label on unit and check input voltage available at site.
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
1 Input Power Conductors (Customer
Supplied Cord)
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow
conductor to supply grounding
terminal first, and never to a line
terminal.
NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be connected to any input power between 208 and
Select size and length of conductors using
Section 5-9. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Welding Power Source Input Power
Connections
2 Strain Relief
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief and tighten screws.
3 Welding Power Source Grounding
Terminal
4 Green Or Green/Yellow Grounding
Conductor
Route green or green/yellow grounding
conductor through current transducer and
connect to welding power source grounding
terminal first.
Reinstall side panel on welding power source.
Disconnect
Connections
Device
Input
Power
7 Disconnect Device (switch shown in the
OFF position)
8 Disconnect Device Grounding Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protection using Section 5-9 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
Input5 2012−05
Notes
OM-250 878 Page 23
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
AccuCurve
CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has
a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.
Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths, better
puddle control, more tolerant of tip-to-work variation, less audible noise, no arc wandering, allows weld to fill in
at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps.
Accuspeed (optional)
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed to be
tight and fast. Front panel display is ACCU − SPED.
Adjust
Control knob used to change or set parameters and functions.
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual
arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in MIG
programs.
Arc Control
Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD
(optional).
Arc Length
Distance from end of wire electrode to workpiece.
Auto Thread
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will
automatically feed wire. Default setting is 72 inches at a feed rate of 700 ipm. Pressing jog, purge, or trigger
switch will terminate the auto-threading feature. These values can be changed using a PDA with File
Management/WaveWriter software.
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (only available on Auto Axcess
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software).
Gas Type
Selection of shielding gas being used in application.
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per
second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes
the welding puddle more fluid.
MIG
CV weld process with individual settings of voltage and wire speed.
Postflow
Setting a time value for gas flow after arc end (only available on Auto Axcess models in the Arc On and Analog
input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File Management software).
Preflow
Setting a time value for gas flow prior to arc start (only available on Auto Axcess models in the Arc On and
Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File
Management software).
Process
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
Process Set Up
Selection procedure for entering program.
Program
Eight active slots for selection of various processes, wire types, and parameters.
Program Load
Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory
taught data. Adaptive method is controlled by frequency adjustment.
Retract
Sequence function that allows the wire to move back towards the contact tip when a welding operation is
completed. Setting is both speed (IPM) and time (sec), (only available on Auto Axcess models in the Arc On
and Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File
Management software).
RMD (optional)
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of RMD are well
suited to thin materials, improves gap filling and spatter reduction. Provides less heat input into workpiece,
minimizes distortion and allows use of larger diameter wire on thin gauge materials.
Sequence
Selecting Sequence will allow setting of preflow, start, crater, postflow, and retract times and parameters (only
available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes).
Sharp Arc
In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory
pulse data. In RMD (optional) this control will affect the arc in much the same way as inductance.
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (only available on Auto Axcess
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software).
Synergic
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse
settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed
speed setting.
OM-250 878 Page 24
6-1 . Operational Terms (Continued)
Time
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in the Arc On
and Analog input or the Arc On and No Analog input modes).
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.
Weld
Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess
models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the
optional PDA with File Management software].
WFS
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In
pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire electrode
(one knob control).
Wire Type
Selection of wire type by alloys and classification.
Table 6-1. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2,
98% Argon/2% O2
CO2
C10
C15
C25
C5
OX5
OX2
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2
(81Ar/18HE/1CO2
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO2
MIG/RMD/Accu-pulse)
OX2
Tri Gas
90% Argon/10% CO2
C10
Cored Tubular Wire
MCOR
71, 76, 86R, 409, 439
Aluminum
ALUM
4XXX, 5XXX
Tri Gas
98% Argon/2% O2
OX2
100% Argon
ARGN
* Not all wire types may be available with your unit.
Notes
OM-250 878 Page 25
6-2. Front Panel Controls
15
14
13
1
4
12
V
A
A
3
11
10
8
5
9
6
7
16
Adjust
Setup
Arc Control
2
. When an LED is lit, it means the related function is active.
1 Program Display
Displays the number of the active program.
2 Adjust Knob
Turn the Adjust knob to change program
number, Setup, Arc Control, and weld
parameters.
The lit LED indicates which setup mode is
active. Setup mode parameters are shown in
Display Windows (see Items 13 and 15).
7 Setup Push Button
Press button to select Process, Wire Type,
Wire Diameter, or Gas Type parameters.
Process LED
. In order for selections to be retained in
The LED lights when the Program Push
Button is active.
When this LED is lit, turn the Adjust knob to
select the desired weld process. Choices
include pulse welding (displayed as PULS),
Accu-pulse, MIG welding (MIG), and Accu
Puls/RMD [Regulated Metal Deposition
(optional)].
4 Program Push Button
Wire Type LED
Press push button (LED lights) and turn
Adjust knob to select active program.
When this LED is lit, turn the Adjust knob to
select the desired wire type, wire alloy, and
size. Wire type and size choices vary
according to the selected weld process.
Choices may include steel (displayed as
STL), stainless steel (SS), metal core
(MCOR), aluminum (ALUM). See Table 6-1
for all wire abbreviations.
3 Program Push Button LED
The letter C is displayed with the program
number if the program has been changed
from the factory settings using the optional
PDA with File Management/WaveWriter
software (see File Management/WaveWriter
Owner’s Manual).
. The program cannot be changed through
the front panel while welding.
Press and hold button to see program name.
Custom programs are named using optional
PDA with File Management/WaveWriter
software. Program name is shown in upper
and lower displays (items 13 and 15).
5 Setup Mode Indicators
OM-250 878 Page 26
219 712-A
Gas Type LED
When this LED is lit, turn the Adjust knob to
select the desired weld gas. Gas type choices
vary according to the selected weld process.
See Table 6-1 for all gas abbreviations.
6 Setup Push Button LED
The LED lights to indicate one of the setup
modes is active.
memory, the Setup push button must be
pressed six times before any other push
button is pressed: once to select
Process, again to select Wire Type, again
to select Wire Alloy, again to select Wire
Size, again to select Gas Type, and a sixth time to store selections in memory. The
displays will temporarily show “PROG
LOAD” to indicate the data is being stored
in memory.
8 Arc Control LED
The LED lights to indicate the Arc Control
button is active. Light goes out when button is
inactive.
9 Arc Control Push Button
This push button allows fine tuning
inductance for MIG programs, and Arc
Control for programs other than MIG. When
the push button is pressed, the upper display
(item 15) shows INDU for inductance, or ARC
for Arc Control to indicate which parameter is
selected for change. The range of possible
values is 0-99 for inductance, and 0-50 for arc
control. Turn the Adjust knob to change the
parameter value. Press button to deactivate
arc control mode (LED goes out).
6-2.
Front Panel Controls − Continued
10 Wire Feed/Gas/Contactor LEDs
The Wirefeed LED lights when the wire feeder
is energized. For example, when the front
panel Jog or Retract button is pressed, the
Wirefeed LED lights.
Display Command Values mode. Only wire
speed command will be displayed while
welding if the unit is set in Display Command
Values mode, even if the Wire Feed
Speed/Amps Display button is pressed.
The Gas LED lights when the gas valve is
energized.
. Displays show actual or command values
The Contactor LED lights when the output
contactor is energized, making the weld
output terminals live.
11 Wire Speed And Amps LEDs
The lit LED indicates whether wire speed or
amps are being displayed.
12 Wire Feed Speed/Amps Display Push
Button
13 Lower Display
Press Wire Feed Speed/Amps Display button
to show weld amperage or wire feed speed in
lower display (the applicable LED under the
lower display lights to indicate which is
shown). When welding, actual value is shown.
If amperage was selected for display, the unit
will show actual welding amperage prior to
and while welding unless the the unit is in
as determined by configuration menu
when using a PDA with File Management/
WaveWriter software. Command values
are displayed prior to welding and actual
values are displayed while welding unless
a PDA with File Management/WaveWriter
software was used to set the unit in the
”Display Command Values” mode. In the
Display Command Values mode,
command values are displayed while
welding.
. If a PDA with File Management/WaveWriter
software is used to change wire feed units
(IPM, MPM) or display welding information
(command or actual),save the changes and
then turn the power to the unit off and then
on again for the changes to be carried out
by the unit.
14 Volts And Arc Adjust LEDs
The lit LED indicates whether voltage or arc
length is being displayed.
15 Upper Display
The upper display shows different information
depending on the active function of the unit
and the weld process being used. When the
display shows voltage (for a MIG process),
the Volts LED lights. When it shows arc adjust
[for a pulsed and RMD (optional) weld
process], the Arc Adjust LED lights. However,
during any weld process (MIG and pulse), the
unit will display actual arc voltage unless a
PDA with File Management/WaveWriter
software has set the unit in the ”Display
Command Values” mode.
16 Lock LED
The lock LED is illuminated when one or more
programs have been locked using an optional
PDA with File Management/WaveWriter
software. This indicates that some programs
have been disabled. A disabled program will
not show up for selection.
Refer to the File Management/WaveWriter
Owner’s Manual for additional information.
6-3. Front Panel Switches
6
3
4
1
8
5
9
7
1 Power Switch
Turns unit On or Off.
AUTO
300
2
The power-up sequence may last up to 30
seconds before the unit is ready to weld.
During power-up, the front panel will display
messages indicating the status of the unit. The
first message is:
AUTO 300 indicates the software being
loaded.
NET
WAIT
3 Purge Push Button
NET WAIT is an abbreviation for ”network
updating” and means the internal control
network is powering up. The next message is
DTEC
ROBT (Robot Type)
The final message is:
2 Contactor LED
Contactor LED illuminates when weld output is
energized.
6 Wirefeed LED
Ref. 803 677-A
Wirefeed LED illuminates when wire feeds or
retracts.
7 Retract Push Button
Press button to retract wire. Wirefeed LED
illuminates when Retract push button is
pressed.
Gas LED illuminates when Purge push button
is pressed.
Auto-Threading feature is activated by
pressing the Jog and Retract buttons
simultaneously. Pressing the Jog, Purge, or
trigger switch will turn off the Auto-Threading
feature.
5 Jog Push Button
8 PDA Port
Press button to jog wire.
9 PC Port
Press button to purge gas line.
4 Gas LED
OM-250 878 Page 27
6-4. Robot Calibration Mode
Use the robot calibration mode to
custom-calibrate the power source to
the robot command signals. This
ensures the wire speed, voltage, and
arc adjust are the same on the robot
pendant as on the power source.
. The factory recommendation is to
DTEC
V
ROBT
A
Adjust
Arc Control
A
Setup
Turn unit On. Unit displays abbreviated name of robot detected.
V
A
A
perform the calibration on all
installations or code updates.
Follow this procedure if the factory
settings are not as accurate as
desired. Synchronization of the robot
and power source signals makes
installation easier and improves the
operation of the system.
. The
robot pendant must have
Weld enabled, and there can be
no start/stop crater conditions set
in the robot.
The calibration mode will execute as a
”dry run” from the operator’s
perspective. The welding power
source provides the robot with
feedback so the robot thinks a weld is
underway, yet the robot torch need not
move during the calibration.
. If
Setup
Adjust
Arc Control
Press Wire Speed/Amps Display push button while abbreviated name of robot appears to enter
calibration mode. ROBT CAL message is displayed. ROBT CAL message will not display until
after the power-up sequence is completed (approximately 20 seconds).
you wish to stop the calibration
procedure, turn unit input power
off and then on again.
If the calibration is performed correctly
the ROBT CAL message stop being
displayed; however, if it is performed
incorrectly, the message remains on
the display.
To start the calibration procedure over
again, turn unit input power off and
then on again following the calibration
setup steps following the calibration
setup steps.
CIRCULER
Use robot pendant or other method to enter two weld schedules into the robot. Maintain schedule 1
for at least 10 to 20 seconds minimum before moving on to schedule 2. Maintain schedule 2 for 10
to 20 seconds before ending the simulated weld. Schedule data is shown below:
Schedule 1
Schedule 2
10.0 Volts
100 IPM
44.0 Volts
1000 IPM
V
A
A
Setup
Adjust
Arc Control
When the robot calibration mode ends, the ROBT CAL message stops and the unit will display
normal front panel information.
219 712-A
OM-250 878 Page 28
6-5. Robot Auto-Calibration Sample Programs
. It is critical to make certain that NO start power, start conditions, run-in, or crater parameters of any kind are present in the robot program. The
welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this
as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second
condition and fail to execute Auto-Cal correctly.
Actual Motoman Welder Condition File
<Welding Current Output Char.>
NO.
REF (V)
MEASURE (A)
01 0.01
1
02 7.00
500
03 13.99
999
04 0.00
0.00
<Welding Voltage Output Char.>
NO.
REF (V)
MEASURE (V)
01 0.14
0.5
02 7.00
25.0
03 14.00
50.0
04
Sample Auto-Calibration Routine For Fanuc Robot
1: Call Safehome
2: J P[1] 40% Fine
Arcstart [10.0Volts, 100.0IPM]
3: L P[2] 10.0 sec Fine
Arc End [0.0Volts, 0.0IPM, 0.0Sec]
4: Wait 1.00 (Sec)
5: J P[3] 40% Fine
Arcstart [44.0Volts, 1000.0IPM]
6: L P[4] 10.0 sec Fine
Arc End [0.0Volts, 0.0IPM, 0.0Sec]
7: Call Safehome
Sample Auto-Calibration Routine For ABB Robot
Sample Auto-Calibration Routine For Motoman Robot
Move J home, v500, z50, tweldgun;
0000 NOP
Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;
0001 Mov J
Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
0002 AWELD 1.40
WaitTime 5;
(AWELD direct input of 1.40Volts = 100 ipm)
0003 VWELD 2.80
Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
(VWELD direct input of 2.80Volts = 10.0 volts)
Move J home, v500, z50, tweldgun;
0004 Arcon
0005 Timer
T=10.00
0006 Arcof
0007 AWELD 14.00
(AWELD direct input of 14.00Volts = 1000 ipm)
0008 VWELD 12.32
(VWELD direct input of 12.32Volts = 44.0 volts)
0009 Arcon
0010 Timer
0011
T=10.00
Arcof
0012 End
*Seam Data values must all be set at zero.
Weld Data 1:
Weld Data 2:
weld_sched:=0
weld_sched:=0
weld_speed:=5
weld_speed:=5
weld_voltage:=10
weld_voltage:=44
weld_wfs:=100
weld_wfs:=1000
org_weldspeed:=0
org_weldspeed:=0
org_weldvoltage:=0
org_weldvoltage:=0
org_weldwfeed:=0
org_weldwfeed:=0
OM-250 878 Page 29
6-6. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
. System configuration data will be
RST
lost during the Reset operation.
V
NO
Setup
A
A
Adjust
Arc Control
Enter reset mode by turning power On and pressing the Program
Push Button until the RST NO message is displayed. RST NO
message will not display until after the power-up sequence is
completed (approximately 20 seconds).
RST
V
YES
Setup
Adjust
RST
V
YES
A
A
Arc Control
Rotate Adjust knob to change NO
to YES.
Setup
Adjust
CYCL
V
PWRA
A
A
Setup
Arc Control
Adjust
A
Arc Control
Press the Arc Control button to
confirm the reset.
Cycl Pwr message appears on the display
when programs complete loading.
The reset message is displayed for
2 seconds while factory program
settings are being reloaded.
Turn power off, wait 10 seconds, and turn
power back on again to complete the reset
operation.
During the reset mode the following
factory default programs are loaded
into the unit:
Program 1
Pulse
.9 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.9 Mild Steel
75% Argon, 25% CO2
Program 3
Accu-pulse
.9 Mild Steel
90% Argon, 10% O2
Program 4
Pulse
1.1 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
1.1 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
1.1 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
1.3 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
1.3 Mild Steel
75% Argon, 25% CO2
. After
Reset is complete, be sure to load
appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation
219 712-A / 803 246-B
OM-250 878 Page 30
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
l Unreadable Labels
~ Weld Terminals
nl Cords
nl Gun Cables
Every
6
Months
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
l Damaged Gas Hose
Reference
nl Weld Cables
OR
~ Drive Rolls
~ Inside Unit
7-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 803 675-A
OM-207 991 Page 31
SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
8-1. Symbol Usage
OM-250 878H - 2014−05, safety_stm 2013-09
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
8-2. Servicing Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.
Only qualified persons should test, maintain, and repair this
unit.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
During servicing, keep everybody, especially children, away.
HOT PARTS can burn.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D
Do not leave live unit unattended.
D
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section before touching any parts.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXPLODING PARTS can injure.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
OM-250 878 Page 32
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep away from pinch points such as drive
rolls.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools
away from moving parts.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts from the manufacturer.
D Read and follow all labels and the Technical Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
D Perform maintenance and service according to the Technical
Manual, industry standards, and national, state, and local codes.
8-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
8-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct 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.
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.
OM-250 878 Page 33
SECTION 9 − TROUBLESHOOTING
9-1. Set Value Mode
V
A
A
1
Setup
Adjust
4
Arc Control
2
3
The Set Value mode is a troubleshooting tool
that allows certain robot command values to
be manually over-ridden.
1
Setup Push Button
2
Arc Control Push Button
3
Adjust Knob
4
Wire Feed Speed/Amps Display Push
Button
Enter the Set Value mode by pressing the
Setup and Arc Control push buttons at the
same time. When in the Set Value mode the
OM-250 878 Page 34
display windows briefly shows SET VALU and
the blinking LEDs under the display windows
indicate whether Volts, Arc Adjust, or Wire
Speed can be changed turning the Adjust
knob.
Depending on the defined weld process,
either volts (MIG) or arc adjust [pulse,
Accu-pulse, or RMD (optional)] can be
changed in the top display. Wire speed can be
changed in the bottom display. Press the Wire
Feed Speed/Amps push button to toggle
between selecting information in the top
display or bottom display. The LED under the
active display will blink to indicate the value
that can be changed.
Rotate the Adjust knob to change values.
Exit the Set Value mode by pressing the Setup
and Arc Control push buttons at the same time
or turning power source off and then back on
again.
Set Value mode overrides robot wire feed
speed, voltage, and trim commands. To weld
in this mode, the robot only needs to provide
a contactor signal, and voltage and wire feed
speed will be ignored.
9-2. Error Code Troubleshooting Tables
ERR
Display Example
TACH
. The following error codes may appear on the upper and lower displays of the User Interface Module
to indicate specific errors. Explanations of
the error codes are provided in the sections referenced.
Error Type
User Interface Module
Upper Display
User Interface Module
Lower Display
Reference
Emergency Stop
E
STOP
Section 9-2. A
Arc Error
ERR
ARC
Section 9-2. B
No Coolant Flow
ERR
COOL
Section 9-2. C
Ground Current
Detect Error
ERR
GND
Section 9-2. D
Line Error
ERR
LINE
Section 9-2. E
Motor Over Current
ERR
MOTR
Section 9-2. F
Arc Start Error
ERR
STRT
Section 9-2. G
No Tach Error
ERR
TACH
Section 9-2. H
Thermal Over
Temperature
ERR
TEMP
Section 9-2. I
Unknown Error
ERR
UNKN
Section 9-2. J
Motor Communications Error
MOTR
COMM
Section 9-2. K
Over Average Current
OVER
AVE
Section 9-2. L
Over Current
OVER
CRNT
Section 9-2. M
Release Trigger
REL
TRIG
Section 9-2. N
Trigger Stuck
TRIG
STUK
Section 9-2. O
Wire Feed Speed
ERR
WFS
Section 9-2. P
Flow Error
ERR
FLOW
Section 9-2. Q
Stop Error
ERR
STOP
Section 9-2. R
Stuck Error
ERR
STUK
Section 9-2. S
Weld Wait
WELD
WAIT
Section 9-2. T
Please Wait
PLS
WAIT
Section 9-2. U
Low Wire Feed Speed
LOW
WFS
Section 9-2. V
Robot Memory
ROBT
MEM
Section 9-2. W
Unit Communication
UNIT
COMM
Section 9-2. X
RMD Done
RMD
DONE
Section 9-2. Y
Gas Flow Error
ERR
GAS
Section 9-2. Z
Robot Communication Error
ROBT
COMM
Section 9-2. AA
Network Wait
NET
WAIT
Section 9-2. AB
Cycle Power
CYCL
PWR
Section 9-2. AC
PCM Bus Communication
——
——
Section 9-2. AD
RIO Bus Communication
——
——
Section 9-2. AE
Wire Feed Bus Communication
——
——
Section 9-2. AF
UIM Bus Communication
——
——
Section 9-2. AG
OM-250 878 Page 35
A.
Emergency Stop Error
Indicates an emergency stop error.
Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board
PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12.
In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.
E
When relay CR1 on E-Stop board PC12 is de-energized, it drops out the 18 volts AC from transformer T1 that powers the
inverter control board(s).
STOP
When relay CR2 on E-Stop board PC12 is de-energized, it breaks the contactor signal being sent to the inverter engine
board(s) from the process control module PC4 (J2-9 to RC2-3) and causes a loss of signal to the AIM board (RC2-1 and
RC2-2) and to micro input (RC5-3 and RC5-4), signaling an E-Stop is active.
When relay CR3 on E-Stop board PC12 is de-energized, it breaks the secondary side output of the motor board before it
goes to the filter board.
Relay CR4 on E-Stop board PC12 is a soft start relay in parallel with the contacts of relay CR1.
B.
Arc Error
ERR
ARC
C.
COOL
GND
LINE
Indicates that primary power has dropped below the operating point of the welding power source. Signal is sent from inverter engine module(s) (RC6, Pin 9 on inverter control board PC1) to process control module PC4 (J2, Pin 1). Check for a
brown-out condition. The primary boost capacitors have dropped below an acceptable minimum voltage threshold.
This circuit monitors the 940 volts primary DC bus voltage across the electrolytic capacitors C1 and C2. Low line is displayed when this voltage drops below 858 volts DC. This could happen when attempting to draw near rated output power
with an input voltage below 190 volts AC, three phase. This causes the boost section to go into current limit trying to supply the output power. Once current limit is reached, the boost section can no longer hold the bus capacitors at 940 volts
DC. The inverter control will also go into an output current limit mode in an attempt to supply output power.
Motor Over Current Error
ERR
MOTR
G.
Indicates that weld current is flowing through the primary ground. This is a latching error and welding power source power
must be cycled off and back on again.
Line Error
ERR
F.
Indicates no coolant flow in water flow switch option. The error may be reset by reestablishing coolant flow to the gun, and
then pressing the Jog/Purge button.
Ground Current Detect Error
ERR
E.
Arc error can be enabled or disabled using an optional PDA with File Management/WaveWriter software.
No Coolant Flow Error
ERR
D.
Indicates voltage has exceeded the programmable limit of a valid arc for the programmed amount of time (default time is
500 ms). Check contact tip, weld conditions, and shielding gas.
Indicates that the motor has been drawing too much current for too long a time period. To remedy this fault, reduce the wire
feed speed or the wire feeder torque load/duty cycle. Press Jog/Purge button to clear error.
Arc Start Error
ERR
STRT
OM-250 878 Page 36
Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at
least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5
volts). This situation is usually attributed to a contact tip or feeder issue. The arc start error parameter can be disabled
using an optional PDA with File Management/Wave Writer software.
H.
No Tach Error
Indicates loss of tachometer feedback. Determine cause of error as follows:
ERR
TACH
I.
S
Press JOG button on the front panel.
S
Does the motor run wide open immediately?
S
YES Replace Motor Board PC6.
S
Does the motor ramp up in speed?
S
YES Bad motor tach. Contact nearest Factory Authorized Service Agent.
S
Does the motor respond at all?
S
YES Contact nearest Factory Authorized Service Agent.
S
Check motor cable. Is it damaged?
S
YES Replace motor cable.
S
NO Contact factory service personnel.
Thermal Over Temperature Error
Indicates one or more of the inverter engines overheated. Sent from inverter engine module(s) (RC6, Pin 12, on inverter
control board PC1) to process control module PC4 (J2, Pin 7). Check fan on inverter engine(s) and weld currents.
This signal is the sum of two conditions: shutdown that comes from the temperature monitoring circuit on the inverter control board, and Pwr-Up-Cnt that generated by the boost section of the inverter control board. When either of these signals
is active, RC6-12 is pulled low (this is the not ready line out of the inverter control board).
Shutdown is active when there is an over-temperature condition on the primary or secondary heatsink or on the boost
inductor. To determine which of the two locations is at fault, check LED 1 and LED 2 on inverter control board PC1.
ERR
TEMP
S
If LED 1 is lit, this indicates an over-temperature condition on the primary heat sink.
S
If LED 2 is lit, this indicates an over-temperature condition on the secondary heat sink or on the boost inductor.
Pwr-Up-Cnt (power up control) monitors primary voltage start-up conditions when the power source is first turned on. This
signal is opto-isolated from the boost section of the inverter control board. The following conditions must be met for the
power source to power up:
S
Auxiliary power board PC3 must be powered up and operating to supply prepower of +15 volts DC to the boost section of inverter control board PC1.
S
The peak voltage of the input line power must be greater than 150 volts peak.
S
The DC bus voltage must be greater than 85% of the rectified line voltage. This bus voltage also turns on the
pre-charge relay.
S
The DC bus voltage must be boosted to greater than 858 volts DC.
If any of these conditions are not met, then receptacle RC6-12 is pulled low and weld output is locked out.
J.
Unknown Error
ERR
UNKN
Indicates error bit from process control module PC4 is set, but error value sent does not match anything defined with the
UIM board PC7.
OM-250 878 Page 37
K.
Motor Communications Error
The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system
motor cable and secondary cables. Separate cable as much as possible.
Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6.
Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1. If there is no voltage present there, check
for 40 volts DC at J16-1 to J16-2. If voltage is present there and neither LED is lit (Red or Green), try to download WFM
code to welding power source. If neither LED turns on after downloading code and cycling power, replace WFM board
PC6.
If LED3 and LED4 are flashing Red or Green or they are solid Red, this indicates the WFM board is still not communicating
with the PCM board PC4. Be sure that the UIM board PC7 is on-line (two green LEDs lit).
MOTR
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
S
Check process control module PC4 for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
If +24 volts is not present at the connector, proceed as follows:
S
Disconnect connector J10 and J11 from WFM board PC6. Check for +24 volts DC at J10-2 (+) and J10-5 (−), and
J11-2 (+) and J11-5 (−). One of the two connectors must measure +24 volts DC to ensures that the Devicenet lines
are being sent from process control module PC4 to WFM board PC6. If +24 volts DC is present at either connector,
replace WFM board PC6.
S
If +24 volts DC is not present at either J10 or J11 connector, check process control module PC4 at connectors J6, J7,
and J8.Remove plugs from connectors and check for +24 volts DC at pin2 (+) and pin 5 (−). If +24 volts DC is not
present at any of the connectors, replace process control module PC4.
COMM
If LED3 and LED4 are both green this indicates that the WFM board went off-line and then recovered which is usually due
to noise interference.
L.
S
Check wire drive motor isolation. Isolated portion of motor housing should not touch robot arm, welding power source
chassis, lifting eye bolts, or weld secondary common. Measure impedance between chassis and both weld secondary
commons. Measure the impedance across motor isolation barrier on motor housing. All measurements should read
high impedance.
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
Over Average Current Error
Output current is exceeding the thermal capabilities of the welding power source for approximately 25 seconds.
Default value is as follows:
Axcess 450 limit is 610 A average
This is a duty cycle error and requires 5 minutes with power on and NO welding to clear the error.
This error indicates that an excessive amount of current was drawn over a short period of time. Over-average current is
drawn for a period of approximately 25 seconds and can also be expressed as exceeding the power source duty cycle.
OVER
AVE
The current limit is as follows:
Axcess 450 is 610 amperes
This alarm cannot be reset. To clear the condition, the power source must be turned on and allowed to idle for approximately 5 minutes. This cooling period is determined by an internal timer, and turn off power will not reset the timer since it is
saved with the Configuration data. After the 5 minute cooling period, press the Jog or Purge button, or cycle power to clear
the alarm.
If this alarm was received by mistake, and the power source did not exceed the duty cycle, check the following:
Check current feedback signal either while welding or connecting to a load bank. Measure between test point TP8 and
grounding strap on process control module PC4. Test point TP8 is located on left-hand side of board, about 1 in. (25 mm)
to the right of connector J11. TP8 is scaled: 1 volt measured equals 100 amperes actual. This measurement should read 0
volts when not welding. If the measurement reads approximately 13 volts DC, disconnect LEM device from engine (one at
a time) to determine if either device is bad. If the voltage reading still does not change, unplug the lower inverter control
board; if the reading remains the same, replace the upper inverter control board. Voltage readings should be present while
welding. If voltage readings are not correct for current feedback scaling, check individual inverter engines.
OM-250 878 Page 38
M.
Over Current Error
Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6,
Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6).
OVER
The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip
this circuit, only a fault will cause an over-current condition. LED4 will be lit on the inverter control board, and power must
be cycled to clear this error.
S
The most likely fault to trip this circuit is an open 940 volts DC bus bleeder resistor, either R1 or R8 on the interconnect
board. An open resistor will cause the bus, which is split between two series capacitors, to become unbalanced. The
capacitor with the open resistor will go to approximately 340 volts DC. The other capacitor will go to approximately 600
volts DC. Normally, both capacitors are at approximately 470 volts DC. The unit will weld like this most of the time. A
16 uF balancing capacitor in series with the transformer can keep the transformer from saturating under these adverse
conditions. Occasionally, the inverter transformer will saturate, and when this happens, it draws a huge amount of
current and trips the over-current circuit. This condition locks off the inverter control board and eventually the bus capacitors will fail. A change to a different resistor eliminated this situation and the problem is no longer an issue.
S
A shorted output diode will cause an over-current error and no weld output will be available.
CRNT
N.
Release Trigger Error
REL
TRIG
O.
This error occurs after a timed weld expires and the trigger is not released. A PDA with File Management/WaveWriter
software can be used to set up timed welds. This is strictly an informational−type error.
Trigger Stuck Error
TRIG
STUK
P.
Indicates a timed weld has expired, but the trigger is still active. Press Jog/Purge button to clear error.
Indicates the welding power source was turned on and the trigger signal attempted to weld. Turn welding power source off
and back on again to clear the error.
This error indicates a trigger source was activated while the power source was being powered up. If the trigger source is
removed, the error can be cleared.
S
Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or
trigger command.
S
If LED2 is lit on ROI board PC10, a contactor signal is being sent from the robot.
Wire Feed Speed Error
ERR
Indicates actual wire feed speed does not match wire feed speed command. Press Jog/Purge button to clear error.
WFS
Q.
Flow Error
ERR
FLOW
R.
Stop Error
ERR
STOP
S.
Indicates no gas flow to the gun. The error may be reset by reestablishing gas flow to the gun, and then pressing the Jog/
Purge button.
Indicates obstructions in the wire feed system or a faulty wire drive system. Check wire feed and wire drive systems.
Press Jog/Purge button to clear error.
Stuck Error
ERR
STUK
Indicates the welding wire is stuck to the workpiece at the end of a weld. May be caused by poor weld conditions. The
error may be cleared by cutting wire from workpiece, and pressing the Jog/Purge button.
OM-250 878 Page 39
T.
Weld Wait Error
WELD
Indicates unit was not ready for a weld sequence. Press Jog/Purge button to clear error.
WAIT
U.
Please Wait Error
PLS
WAIT
V.
Low Wire Feed Speed Error
LOW
WFS
W.
Indicates user interface board lost data communications. Press Jog/Purge button to clear error. If condition persists, contact nearest Factory Authorized Service gent.
Indicates actual wire feed speed is lower than wire feed speed command. Check for obstructions in the wire feed system
or a faulty wire drive system. Press Jog/Purge button to clear error.
Robot Memory Error
ROBT
Indicates robot lost memory data. Press Jog/Purge button to clear error.
MEM
X.
Unit Communication Error
UNIT
Indicates the data bus on the PCM board is not functioning properly. Press Jog/Purge button to clear error.
COMM
Y.
RMD Done Message
RMD
DONE
Z.
Indicates the RMD demo is completed. Pressing Jog/Purge button will change the screen to CYCL PWR on the display.
Turn unit power off and back on again.
Gas Flow Error
ERR
GAS
Indicates no gas flow to the gun. The error may be reset by re-establishing gas flow to the gun, and then pressing the Jog/
Purge button.
AA. Robot Communication Error
ROBT
COMM
OM-250 878 Page 40
The robot I/O module has lost communication with the welding power source. Contact factory service department for
assistance.
AB. Network Wait
NET
Indicates that the UIM board PC7 is no longer communicating with the PCM board PC4 by DeviceNet.
WAIT
AC. Cycle Power
CYCL
Request to cycle power from the welding power source. Turn unit power off and back on again.
PWR
AD. PCM Bus Communication
——
——
— — Indicates no error message on the displays. PCM board PC4 DeviceNet has gone offline. Turn welding power
source off and back on again to clear the communication error.
AE. RIO Bus Communication
——
——
— — Indicates no error message on the displays. RIO DeviceNet is losing packets of data. Turn welding power source off
and back on again to clear the communication error.
AF. Wire Feed Bus Communication
——
——
— — Indicates no error message on the displays. WFM board PC6 DeviceNet is losing packets of data. Turn welding
power source off and back on again to clear the communication error.
AG. UIM Bus Communication
——
——
— — Indicates no error message on the displays. UIM board PC7 DeviceNet is losing packets of data. Turn welding power source off and back on again to clear the communication error.
OM-250 878 Page 41
9-3. Removing Cover and Measuring Input Capacitor Voltage
Tools Needed:
!
Turn Off welding power
source, and disconnect
input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
8 mm (5/16 in.)
1
2
Turn Off welding power source, and
disconnect input power.
Remove cover
+ lead to left bus terminal, − lead to right bus terminal
1
Power Interconnect Board
PC2
2
Voltmeter
Measure the DC voltage across the
+ bus terminal and − bus terminal on
PC2 as shown until voltage drops to
near 0 (zero) volts. Measure input
capacitor voltage on inverter
assembly before proceeding.
. If the capacitor voltage does
not drop to near zero after
several minutes, use a bleeder
resistor of between 25 and
1000 ohms, at least 5 watts,
#16 AWG 1000 volts DC
insulating rating wire
to
discharge the capacitor(s).
3
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit.
Reinstall cover when finished.
3
Typical Bleeder Resistor
25 to 1000 ohm, 5
watt resistor
#16 AWG 1000 volts
DC insulation rating,
approx 76 mm (3 in.)
leads
802 985 / 248 891-A
OM-250 878 Page 42
9-4. Process Control Module PC4 Diagnostic LEDs
1
Process Control Module PC4
Diagnostic LEDs are visible inside unit,
located on PC4 mounted on the top tray.
Refer to Section 9-5 for information on
diagnostic LEDs.
1
Reinstall cover after checking diagnostic
LEDs.
LED1
LED2
LED3
LED4
216 956-A / 248 891-A
9-5. Diagnostic LEDs On Process Control Module PC4
LED
Status
1
On
Indicates −25 volts DC is present on process control module PC4
Off
Indicates −25 volts DC is not present on process control module PC4
On
Indicates +25 volts DC is present on process control module PC4
Off
Indicates +25 volts DC is not present on process control module PC4
On
See Network Status Table in Section 9-10
Off
See Network Status Table in Section 9-10
2
3,4
Diagnosis
OM-250 878 Page 43
9-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings
1
2
Wire Feed Module PC6
Diagnostic LEDs are visible inside
unit, located on PC6 mounted on
the top tray assembly.
Refer to Section 9-7 for information
on diagnostic LEDs.
Reinstall top cover after checking
diagnostic LEDs.
1
LED1
LED2
2
Dip Switch S1
Dip switches are used to identify
each circuit board on the internal
network. Dip switch settings are
different for each circuit board. For
proper operation, do not change dip
settings from those shown.
LED3
LED4
217 333-B / 804 575-A
9-7. Diagnostic LEDs On Wire Feed Module PC6
LED
Status
1
On
Indicates +15 volts DC is present on wire feed module PC6
Off
Indicates +15 volts DC is not present on wire feed module PC6
On
Indicates +5 volts DC is present on wire feed module PC6
Off
Indicates +5 volts DC is not present on wire feed module PC6
On
See Network Status Table in Section 9-10
Off
See Network Status Table in Section 9-10
2
3,4
OM-250 878 Page 44
Diagnosis
9-8. User Interface Module PC7 Diagnostic LEDs
1
User Interface Module PC7
Diagnostic LEDs are visible inside
unit, located on PC7 mounted behind the front panel.
LED1 Refer to Section 9-9 for information
on diagnostic LEDs.
Reinstall top cover after checking
LED2 diagnostic LEDs.
1
227 542-C / 804 575-A
9-9. Diagnostic LEDs On User Interface Module PC7
LED
Status
Diagnosis
1, 2
On
See Network Status Table in Section 9-10
Off
See Network Status Table in Section 9-10
OM-250 878 Page 45
9-10. Network And Module Status LEDs
A.
Network Status LEDs
The following are network status LEDs:
LED1 on the UIM circuit board
LED4 on the WFM and PCM circuit boards
Status
Diagnosis
Off
The circuit board is not on-line with the network or there is no power applied to the circuit board.
Green
The circuit board is operating normally and the on-line connection is made with the network.
Flashing Green
Red
B.
The circuit board is wait for an on-line connection to be made with the network.
The circuit board has encountered a communication link failure with the network. Check DeviceNet cable connections. Verify
dip switch positions according to Sections 1-2 and 1-3. Replace circuit board if necessary.
Module Status LEDs
The following are module status LEDs:
LED2 on the UIM circuit board
LED3 on the WFM and PCM circuit boards
Status
Diagnosis
Off
There is no power applied to the circuit board or the board software is not executing its functions.
Green
The circuit board is operating normally.
Flashing Red
Red
The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.
The circuit board has encountered an unrecoverable fault.
9-11. Troubleshooting
Trouble
No weld output; completely inoperative
Remedy
Place line disconnect in On position (see Section 5-13).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-13).
Check for proper input power connections (see Section 5-13).
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 5-5).
errors displayed.
Check that proper program for wire size, process, and shielding gas is loaded.
Clean and tighten all weld connections.
No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1.
Wire does not feed.
Check supplementary protector CB2 and reset if necessary.
Check motor control cable connections.
Wire feeds erratically.
Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check robot contactor status.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Check voltage sense lead connection, clean and tighten if necessary.
Gas does not flow or does not stop flow- Check gas valve and flow meter.
ing; wire feeds.
Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.
using electrode negative (straight
polarity) process.
OM-250 878 Page 46
SECTION 10 − ELECTRICAL DIAGRAMS
263 495-A (Part 1 Of 2)
Figure 10-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)
OM-250 878 Page 47
Figure 10-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)
OM-250 878 Page 48
263 495-A (Part 2 Of 2)
OM-250 878 Page 49
Ref. 219 267-B
Figure 10-3. Circuit Diagram For Peripheral/Motor Interface
OM-250 878 Page 50
Notes
OM-250 878 Page 51
SECTION 11 − PARTS LIST
. Hardware is
common and
not available unless listed.
2
3
4 − Fig 11-3
7
5 − Fig 11-2
6 − Fig 11-4
11
15
16
12
9
17
1
10
8
7
18
13
14 − Fig 11-5
250 893-C
Figure 11-1. Main Assembly
OM-250 878 Page 52
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . 210492
. . . 2 . . . . . T2 . . . . . . . 212543
. . . 3 . . . . . . . . . . . . . . . . 210481
. . . 4 . . . . . . . . . . . . . . . . Fig 11-3
. . . 5 . . . . . IM1 . . . . . . 214597
. . . . . . . . . . . IM1 . . . . . . 242680
. . . 6 . . . . . . . . . . . . . . . . Fig 11-4
. . . 7 . . . . . . . . . . . . . . . . 227792
. . . 8 . . . . . . . . . . . . . . . . 210482
. . . 9 . . . . . . . . . . . . . . . . 213386
. . . 10 . . . . HD2 . . . . . . 182918
. . . 11 . . . . . . . . . . . . . . . . 229967
. . . 12 . . . . . . . . . . . . . . . . 148025
. . . 13 . . . . . . . . . . . . . . . . 213372
. . . 14 . . . . . . . . . . . . . . . . Fig 11-5
. . . 15 . . . . . . . . . . . . . . . . 247392
. . . 16 . . . . . . . . . . . . . . . . 204846
. . . 17 . . . . . . . . . . . . . . . . 220377
. . . 18 . . . . . . . . . . . . . . . . 220376
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, LH w/Components (Fig 11-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (Fig 11-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 878 Page 53
14
. Hardware is
common and
not available unless listed.
15
2
1
3
4
5
13
6
7
12
11
8
9
33
10
6
34
35
7
17
16
18
19
32
31
20 21
30
29
23
24
25
23
27
13
36
28
26
22
23
38
37
802 955-C
Figure 11-2. Windtunnel Assembly LH And RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Windtunnel Assembly LH And RH (Fig 11-1 Item 6)
... 1 ................
... 2 ................
. . . 3 . . . . . L1 . . . . . . .
... 4 ................
. . . 5 . . . R3, C4 . . . . .
... 6 ................
. . . 7 . . . D1, D2 . . . . .
... 8 ................
... 9 ................
. . . 10 . . . . . T1 . . . . . . .
. . . 11 . . . . . Z1 . . . . . . .
. . . 12 . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . .
......................
......................
. . . . . . . . . . CT1 . . . . . .
. . . 20 . . . . . . . . . . . . . . . .
214597
196351
213940
214519
233052
199840
201531
196347
196349
203408
220496
170647
179276
196355
010546
242680
196332
030170
196259
115092
115091
196231
201695
. . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . .
. . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
2
4
6
1
1
1
2
1
1
1
1
2
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 878 Page 54
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Windtunnel Assembly LH And RH (Continued)
. . . 21 . . . C1, C2 . . . . .
. . . 22 . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . .
. . . 24 . . RT1, RT2 . . . .
. . . 25 . . . . PC2 . . . . . .
. . . 26 . . . . . C3 . . . . . . .
. . . 27 . . . . . . . . . . . . . . . .
. . . 28 . . . . HD1 . . . . . .
......................
. . . 29 . . . R1, R2 . . . . .
......................
. . . 30 . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . .
. . . 34 . . . . . L2 . . . . . . .
. . . 35 . . . . . . . . . . . . . . . .
......................
......................
. . . 36 . . . . PC1 . . . . . .
. . . 37 . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . .
203912
210507
261556
214015
259491
196143
196378
182918
196384
196343
196840
109056
196514
196512
196330
196345
196588
196365
199136
239612
204846
083147
. . . . Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . .
. . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . .
. . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . .
. . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Control (Inverter 400A) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . .
2
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
4
4
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 878 Page 55
. Hardware is
common and
not available unless listed.
1
2
3
4
5
11
6
10
7
9
8
802 916-C
Figure 11-3. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Top Tray Assembly (Fig 11-1 Item 4)
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
. . . . PC12 . . . . . .
. . . . PC3 . . . . . .
................
................
................
. . . . PC4 . . . . . .
................
................
................
................
. . . . PC6 . . . . . .
239623
239598
210490
134201
083147
221277
170647
210491
223439
198122
221280
. . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . .
. . . Process Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . .
. . . Wire Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
24
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 878 Page 56
. Hardware is
common and
not available unless listed.
15
4
1
2
3
13
5
6
12
14
7
11
16
8
9
10
804 577-B
Figure 11-4. Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Rear Panel Assembly (Fig 11-1 Item 8)
. . . 1 . . . . . . . . . . . . . . . . 217297 . . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . 210479 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . . 210358 . . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . . 210505 . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . . 224012 . . . Plate, Rotation Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . . . 198956 . . . Receptacle, Devicenet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . CB1 . . . . . . 083432 . . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . 9 . . . . CB2 . . . . . . 093995 . . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . 10 . . . . PC11 . . . . . . 239631 . . . Circuit Card Assy, Motor Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . 216596 . . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . . 225955 . . . Plate, Mounting E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . RC2 . . . . . . 604176 . . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-Stop Connector Factory Installed Option For Axcess (includes) . . . .
. . . 14 . . . . PC14 . . . . . 227901 . . . . E-Stop Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . 228694 . . . . Jumper,Connector W/Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . PC22 . . . . . . 243799 . . . Circuit Card Assy,W/Touch Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*Recommended Spare Parts.
OPTIONAL
+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-250 878 Page 57
. Hardware is common and
not available unless listed.
2
21
11
1
7
20
4
19
5
3
18
7
6
8
9
10
17
7
11
14
12
13
15
16
16
803 682-B
Figure 11-5. Front Panel Assembly
OM-250 878 Page 58
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Front Panel Assembly (Fig 11-1 Item 14)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
. . . . . S1 . . . . . . .
................
................
................
. . . . . FM . . . . . . .
. . . . PC13 . . . . . .
. C6, C7, C8 . . .
. . . . RC5 . . . . . .
................
................
................
................
................
................
................
................
PB1, PB2, PB3 . .
................
................
................
................
207456
207895
179851
233576
196313
239619
222488
214664
216965
216966
213102
210866
210477
219843
207979
186621
199443
228917
210865
210483
210358
. . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . .
. . . Panel, PC Card Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy,ISO/COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . .
. . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . .
. . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
3
1
1
1
2
1
1
1
1
2
3
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 878 Page 59
Notes
OM-250 878 Page 60
Effective January 1, 2014
(Equipment with a serial number preface of ME 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 below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Guns
thirty (30) days of such defect or failure, at which time Miller will
* Remote Controls and RFCS-RJ45
provide instructions on the warranty claim procedures to be
* Replacement Parts (No labor)
followed.
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
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 twelve months
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 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No 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
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
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.)
RFCS Foot Controls (Except RFCS-RJ45)
Fume Extractors − Filtair 130, MWX and SWX Series
HF Units
ICE/XT Plasma Cutting Torches (No Labor)
Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
LiveArc Welding Performance Management System
Load Banks
Motor Driven Guns (except Spoolmate Spoolguns)
PAPR Blower Unit (No Labor)
Positioners and Controllers
Racks
Running Gear/Trailers
Spot Welders
Subarc Wire Drive Assemblies
Water Coolant Systems
TIG Torches (No Labor)
Wireless Remote Foot/Hand Controls and Receivers
Work Stations/Weld Tables (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 2014-04-14
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
 2014 Miller Electric Mfg. Co.
2014−01