Miller AUTO-AXCESS 450 User manual

Miller AUTO-AXCESS 450 User manual
OM-210 540E
January 2004
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 450

Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System 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 catalog 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 7/03
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 − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Rear Panel Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Front Panel Controls (See Section 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Front Panel Controls - Continued (See Section 4-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Special Teach Mode (Use With Section 4-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Special Teach Mode (Use With Section 4-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Pulse Welding Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Teach Data Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
5
5
7
8
8
9
9
9
10
10
11
11
12
12
13
14
14
15
15
16
16
17
18
19
19
20
20
21
22
23
23
23
24
24
TABLE OF CONTENTS
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Front Panel Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Weld Process Board PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Diagnostic LED’s On Process Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Motor Board PC6 Diagnostic LED’s And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Diagnostic LED’s On Motor Board PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Display Module PC7 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Diagnostic LED’s On Display Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Automation Module PC9 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Diagnostic LED’s On Automation Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Network Status Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Robot Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Robot Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
25
25
25
26
27
28
28
29
29
30
30
31
32
33
34
35
36
38
42
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y 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.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
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 connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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 Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not 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 drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld 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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
Return To Table Of Contents
OM-210 540 Page 1
ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays 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 a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D 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 and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL 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.
OM-210 540 Page 2
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
Return To Table Of Contents
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
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
OVERUSE can cause OVERHEATING
D
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.
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.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Return To Table Of Contents
OM-210 540 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-210 540 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Return To Table Of Contents
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder 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 de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
Revenez à la table des matières
OM-210 540 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
D
D
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LE SOUDAGE peut causer un incendie ou une explosion.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer 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 Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer 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 agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-210 540 Page 6
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, 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 poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
Revenez à la table des matières
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
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.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique 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 imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives 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.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
Revenez à la table des matières
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-210 540 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-210 540 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
Revenez à la table des matières
SECTION 3 − INSTALLATION
NOTE
Appearance of actual unit may vary from unit shown in manual.
3-1. Specifications
Input
Power
Rated
Welding
Output
Voltage
Range
Amperage
Range In
CC Mode
Wire Feed
Speed
Range**
Wire
Diameter
Range
Three
Phase
230 V
Input: 450
A@
44 V DC,
100%
Duty
Cycle;
10-44
5-600 A
Standard:
50-1400
ipm
(1.3-35.6
mpm)
.030-.062 in
(0.8-1.6
mm)
460 V
Input: 450
A@
44 V DC,
100%
Duty
Cycle
Max
Open
Circuit
Voltage
DC
80
Amperes Input At Rated Load Output 60 Hz,
Three-Phase
208 V
230 V
400V
460 V
575 V
67.0
(0-1A*)
59.0
(0-1A*)
34.0
(0-1A*)
29.0
(0-1A*)
23.0
(0-1A*)
Input
kVA
Input
KW
23.8
(0.8*)
22.9
(0.17*)
*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.
3-2. Dimensions And Weight
Hole Layout Dimensions
A
A
17-3/32 in (434 mm)
B
17-3/8 in (441 mm)
C
19-3/32 in (485 mm)
D
16-3/32 in (409 mm)
E
1/2 in (13 mm)
E
22-1/2 in
(572 mm)
31 in
(787 mm)
C
B
Weight
17-3/32 in
(434 mm)
163 lb (74 kg) Net
175 lb (79 kg) Ship
D
Return To Table Of Contents
803 244-B
OM-210 540 Page 9
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void warranty.
100% Duty Cycle At 450 Amperes
60% Duty Cycle At 580 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 181 560
3-4. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
CV MODE
80.0
70.0
. This volt-ampere curve repre-
VOLTAGE
60.0
sents the dynamic output of the
unit with a static load.
50.0
40.0
30.0
20.0
10.0
0.0
0.0
100.0
200.0
300.0
400.0
500.0
600.0
700.0
AMPERAGE
OM-210 540 Page 10
Return To Table Of Contents
800.0
900.0
va_curve1 4/95
3-5. Selecting A Location
Movement
Tipping
Y Do not move or operate
unit where it could tip.
2
OR
1
Location
Y Special installation may be required where gasoline or volatile
liquids are present − see NEC Article 511 or CEC Section 20.
Y Do not stack units. Beware of
tipping.
1
Lifting Forks
Use lifting forks to move unit.
4
Extend forks beyond opposite side
of unit.
3
2
Hand Cart
Use cart or similar device to move
unit.
18 in
(460 mm)
3
Rating Label
Use rating label to determine input
power needs.
4
Line Disconnect Device
Locate unit near correct input
power supply.
18 in
(460 mm)
loc_2 3/96 -803 244-B
3-6. Connection Diagram
. The proper interface kit must
2
be installed in the welding power source/interface unit to allow
it to be connected to the robot.
5
3
1
4
1
6
7
12
10
Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 Robot Input/Output Cable
7 Gas And Motor Control Cable
8 Welding Power
Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
11 Voltage Sensing Lead
(Optional)
. Positive
11
8
9
(+) voltage sensing
lead is contained in the motor
cable.
12 Positive (+) Weld Cable
803 244-B / Ref. 801 915-A
Return To Table Of Contents
OM-210 540 Page 11
3-7. Rear Panel Receptacles And Circuit Breakers
4
5
6
1
1
2
3
2
115 V 10 A AC Receptacle RC2
Receptacle supplies 60 Hz singlephase power. Maximum output from
RC2 is limited by circuit breaker CB2 to
10 amps.
Circuit Breaker CB1
Circuit Breaker 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
Use receptacle to connect gas and motor control cable to power source (see
Section 3-6).
5
Peripheral Receptacle RC25
Receptacle provides connection to
touch sensor, water flow switch, jog +/−,
and n/o relay contacts circuitry (see
Section 3-10).
6
Robot Interface Receptacle RC72
Use receptacle to connect robot input/
output cable.
Ref. 803 245-B
3-8. Connecting To Weld Terminals
Y Turn off power before connecting to weld output terminals.
1
2
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
Connect positive weld cable to
Positive (+) weld terminal and
negative (−) cable to Negative
weld terminal.
1
Tools Needed:
2
3/4 in
OM-210 540 Page 12
803 244-B
Return To Table Of Contents
3-9. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Y Turn off power before
connecting to weld output terminals.
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
10 − 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Return To Table Of Contents
OM-210 540 Page 13
3-10. Peripheral Receptacle Functions
Contact closure to B dependent upon state of
programmed output.
B
Contact closure to A dependent upon state of
programmed output.
C*
Circuit common.
D
Contact closure to C completes 24 volts dc
solenoid circuit to purge shielding gas line.
E
Contact closure to F indicates coolant flow switch is
closed and recirculating coolant system is
operational.
F*
Circuit common.
Jog +
H**
Contact closure to circuit common advances
welding wire at wire drive assembly.
Jog −
J**
Contact closure to circuit common retracts welding
wire at wire drive assembly.
K
Contact closure to L energizes Touch Sensor
circuitry.
L*
Circuit common.
M
Part touched +24 volts dc output signal referenced
to circuit common.
Programmable
Output Relay ConCon
tacts
D
E
Socket Information
A
F
L
Socket
C
B
A
M
K
J
H
Function
Purge
Coolant Flow
Switch Input
Signal
Touch Sensor ON
And Output Signal
Ref. 803 245-B
*Circuit common is same electrical reference point.
**Speed of Jog + and Jog − is at setup value for Jog IPM parameter.
Note: A customer supplied matching amphenol plug (Part No. MS3106A20-33P and strain relief clamp AN3057-12) is required to use peripheral
receptacle.
3-11. Electrical Service Guide
60 Hz
Input Voltage
208
230
400
460
575
Input Amperes At Rated Output
67
59
34
29
23
Time-Delay 2
80
70
40
35
25
Normal Operating 3
100
90
50
45
35
4
6
8
10
10
173
(53)
136
(42)
263
(80)
228
(69)
356
(108)
8
8
8
10
10
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
OM-210 540 Page 14
Return To Table Of Contents
3-12. Connecting Input Power
Y Turn Off welding power source,
and check voltage on input capacitors according to Section
6-4 before proceeding.
Y Incorrect connections will
cause electric shock and damage to the machine.
1
Y Have only qualified persons
perform these connections according to all applicable codes
and safety practices.
Y Disconnect input power before
opening door for voltage connections.
3
1
L1
L2
Clamp
Install clamp of proper size for unit and
input conductors.
2
2
Input And Grounding Conductors
Select size and length using Section
3-11.
L3
Connect input conductors as shown in
illustration.
= GND/PE
Connect grounding conductor first,
then line input conductors. Always
connect green wire to supply grounding terminal, never to a line terminal.
Y Always connect grounding
conductor first.
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
Tools Needed:
WARNING
5/16 in
ELECTRIC SHOCK can kill;
SIGNIFICANT DC VOLTAGE
exists after removal of
input power.
Double-check grounding conductor,
inside voltage connections, and input
voltage before applying power.
3
Line Disconnect Device
See Section 3-11.
Close door before operating unit.
S Always wait 5 minutes after power
Is turned off before working on unit.
S Check input capacitor voltage, and
be sure it is near 0 before touching
any parts.
Read Owner’s Manual.
Three-Phase Input Connection
Route input power cable
through tubing inside unit.
Route ground conductor through
current transducer to ground terminal.
803 245-C / 218 005-A
3-13. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.
The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral
receptacle. Turning on touch sensor causes a dc voltage to be present on the welding wire. When welding wire
touches the weldment, the voltage sensing circuit closes, and a +24 volts dc output signal is sent to the robot control
indicating weldment detection. Touch sensor dc voltage on the welding wire is 80 volts DC. As soon as touch sensor
turns on, WIRE LIVE appears on the front panel display.
Return To Table Of Contents
OM-210 540 Page 15
SECTION 4 − OPERATION
4-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Adaptive Pulse Welding
When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate
pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stickout.
Abk (Background Amperage)
Abk is the low weld current. Background current preheats welding wire and maintains the arc. When
background current is too low, the arc is unstable and hard to maintain.
Apk (Peak Amperage)
Apk is the high pulse of welding current. Peak current melts the welding wire and forms a droplet. The
droplet is forced into the weld puddle.
Vpk (Peak Voltage)
Arc voltage during peak current phase of the pulse waveform. This determines arc length during
adaptive pulse welding.
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit
metal transfers per second (provided no other changes are made) and increase the arc-on time. The
increased arc-on time makes the pool more fluid.
PPS (Pulses Per Second)
PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse rate of 60 Hz means
60 pulses of current are produced each second.
PWms (Pulse Width in Milliseconds)
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time must be long enough to
form a droplet of welding wire. The stiffness or fluidity of the molten weld puddle is controlled by
PWms.
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.
Trim
Term used to represent arc length adjustments in pulse programs. Increasing trim increases the actual arc length. Likewise, decreasing trim shortens arc length. Trim is replaced by volts in MIG programs.
OM-210 540 Page 16
Return To Table Of Contents
4-2. Front Panel Controls (See Section 4-3)
15
13
14
1
4
12
Program
Volts
Arc Length
Wire Speed
3
Amps
11
Process
Wirefeed
Wire Type
Gas Type
Gas
Contactor
10
5
6
8
7
Setup
Adjust
Arc Control
9
2
. When an LED is lit, it means the related function is active.
198 993
1
Program Display
Displays the number of the active program.
2
Adjust Control
dant. Program name is shown in upper and
lower displays (items 13 and 15). Display
reads ”AAAA” if no name is assigned to program.
Use the Adjust control to change program
number, Setup and Arc Control parameters.
5
3
The lit LED indicates which setup mode is active. Setup mode parameters are shown in
Display Windows (see Items 13 and 15).
Program Push Button LED
The LED lights when the Program Push Button is active and the Adjust control can be
used to change the program. LED goes out
when Program push button is inactive.
4
Program Push Button
Press push button (LED lights) and turn Adjust
control to select active program. Press button
again to deactivate button (LED goes out).
The letter C is displayed with the program
number if the program has been changed from
the factory settings using the optional control
pendant (see Pendant Owner’s Manual).
. The program cannot be changed through
the front panel while welding.
Press and hold button to see program name
assigned by user using optional control pen-
Setup Mode Indicators
Process LED
When this LED is lit, turn the Adjust control to
select the desired weld process. Choices include pulse welding (displayed as PULS) and
MIG welding (MIG).
Wire Type LED
When this LED is lit, turn the Adjust control to
select the desired wire type 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), 4043 aluminum (AL4X),
and 5356 aluminum (AL5X). See Table 4-1 for
all wire abbreviations.
Return To Table Of Contents
Gas Type LED
When this LED is lit, turn the Adjust control to
select the desired weld gas. Gas type choices
vary according to the selected weld process.
Some choices may include:
100% argon (displayed as ARGN GAS)
90% argon, 10% CO2 (C10 GAS)
98% argon, 2% CO2 (C2 GAS)
98% argon, 2% O2 (OX2 GAS).
See Table 4-2 for all gas abbreviations.
6 Setup Push Button LED
The LED lights to indicate one of the setup
modes is active.
7 Setup Push Button
Press button to select Process, Wire Type, or
Gas Type parameters.
. In order for selections to be retained in
memory, the Setup push button must be
pressed four times before any other push
button is pressed: once to select Process,
again to select Wire Type, again to select
Gas Type, and a fourth time to store
selections in memory. The displays will
temporarily show “PROG LOAD” to indicate the data is being stored in memory.
OM-210 540 Page 17
4-3. Front Panel Controls - Continued (See Section 4-2)
8
11 Wire Speed And Amps LED’s
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 Sharp Arc for programs other than MIG. When the push button
is pressed, the upper display (item 15) shows
INDU for inductance, or ARC for Sharp Arc to
indicate which parameter is selected for
change. The range of possible values is 0-99
for inductance, and 0-20 for sharp arc. Turn
the Adjust control to change the parameter
value. Press button to deactivate arc control
mode (LED goes out).
10 Wire Feed/Gas/Contactor LEDs
The Wirefeed LED lights when the wire feeder
is energized. For example, when the front
panel Jog or Retract button is pressed, the
Wirefeed LED lights.
The Gas LED lights when the gas valve is energized.
The Contactor LED lights when the output
contactor is energized, making the weld output terminals live.
Table 4-1. Welding Wire
Abbreviations*
Wire
Description
Abbreviation
Steel
(ER70 S-3)
ER70 S-6)
Stainless Steel
(ER309L)
STL
Cored
Tubular Wire
(Metalox 76)
MCOR
SS
Aluminum
(ER5356)
AL5X
Aluminum
(ER4043)
AL4X
* Not all wire types may be
available with your unit.
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 optional control
pendant was used to set the unit in Display
Command Values mode. Only wire speed
command will be displayed while welding if the
unit is set in Display Command Values mode,
even if the Wire Feed Speed/Amps Display
button is pressed.
. Displays show actual or command values
as determined by configuration menu in
optional control pendant. Command values are displayed prior to welding and actual values are displayed while welding
unless the optional control pendant was
Table 4-2. Welding Gas
Abbreviations*
Full Gas Name
100% CO2
100% Argon
75% Argon, 25% CO2
80% Argon, 20% CO2
85% Argon, 15% CO2
90% Argon, 10% CO2
92% Argon, 8% CO2
95% Argon, 5% CO2
98% Argon, 2% CO2
90% Argon, 7-1/2%
CO2, 2 1/2% O2
95% Argon, 5% O2
98% Argon, 2% O2
90% Helium, 7-1/2% Ar,
2-1/2% CO2
75% Helium, 25% Ar
55% Helium, 42-1/2% Ar,
2-1/2% CO2
50% Helium, 50% Ar
25% Helium, 75% Ar
Displayed Gas Name
(4 Digits Only)
CO2
ARGN
C25
C20
C15
C10
C8
C5
C2
ACOX
OX5
OX2
HE90
HE75
HE55
HE50
HE25
* Not all wire types may be available with
your unit.
OM-210 540 Page 18
Return To Table Of Contents
used to set the unit in the ”Display Command Values” mode. In the Display Command Values mode, command values are
displayed while welding.
. If the optional control pendant is used to
change the unit display language (English, French, German, etc.,), 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 Length LED’s
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 length
(for a pulsed weld process), the Arc Length
LED lights. However, during any weld process
(MIG and pulse), the unit will display actual arc
voltage unless the optional control pendant
has set the unit in the ”Display Command Values” mode.
Table 4-3. Robot Abbreviations*
Robot Abbreviations*
Manufacturer
Abbreviation
ABB . . . . . . . . . . . . . . . . . . . ABB
Fanuc . . . . . . . . . . . . . . . . FANU
Daihen . . . . . . . . . . . . . . . DAHN
Kawasaki . . . . . . . . . . . . . KAWA
Motoman . . . . . . . . . . . . . . MOTO
Kuka . . . . . . . . . . . . . . . . . KUKA
Comau . . . . . . . . . . . . . . . COMU
Hitachi . . . . . . . . . . . . . . . . . HCHI
Nachi . . . . . . . . . . . . . . . . . . NCHI
Panasonic . . . . . . . . . . . . . PANA
Reis . . . . . . . . . . . . . . . . . . . REIS
Robot Adapter . . . . . . . . . . DTEC
Detect Disabled . . . . . . . . . OFF
* An abbreviation of NONE means
no robot is detected.
4-4. Front Panel Switches
2
1
5
3
4
Ref. 803 246-B
1
Power Switch
Turns unit On or Off.
The power-up sequence may last up to 20
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
450
AUTO 450 indicates the software being
loaded. The next message is:
NET
WAIT
NET WAIT is an abbreviation for ”network updating” and means the internal control network
is powering up. The final message is
ABB
ROBT
ABB ROBOT identifies the robot adapter being used as identified by the unit. In this example robot adapter ABB is shown. However, any
of the robot adapters listed in Table 4-3 could
be displayed. To ensure proper operation of
the system, verify the robot displayed corresponds to the actual robot being used.
2
Purge Push Button
Press button to purge gas line.
3
Jog Push Button
Press button to jog wire.
4
Retract Push Button
Press button to retract wire.
5
COM Port
4-5. Special Teach Mode (Use With Section 4-6)
6
5
Program
1
Volts
Arc Length
Wire Speed
Amps
7
Process
Wirefeed
Wire Type
Gas Type
Gas
Contactor
3
2
Setup
Adjust
Arc Control
4
Return To Table Of Contents
OM-210 540 Page 19
4-6. Special Teach Mode (Use With Section 4-5)
Table 4-4. Special Teach Mode Abbreviations
The Special Teach mode is a ”hidden” menu, accessible through the front panel, that allows special configuration information to be changed without using the optional control pendant. The front
panel Special Teach mode is provided for cases
when the control pendant is not available. Information available in the Special Teach menu is
shown in Table 4-4. See Section 4-7 for a definition of pulse welding terms and Section 4-8 for a
teach mode example.
1
2
3
4
5
6
Abbreviation
In Top Display
Program Push Button
Setup Push Button
Arc Control Push Button
Adjust Control
Lower Display
Upper Display
Use the Adjust control to change the information
in top and bottom display windows. The top display is active if the Volts LED is blinking and the
bottom display is active if the Wire Speed LED is
lit. Push the Wire Speed/Amps Display push button to make the upper or lower display window active.
“TPNT” means “teach point”. The following values can be changed using the Adjust control:
inches per minute (displayed as IPM), peak voltage (Vpk), peak current (Apk), background current (Abk), frequency (PPS), pulse width in milliseconds (PWMS), and the ramp value in amps
per milliseconds. Ramp shows the rise in current
waveform as it enters and exits the peak state.
The definition of the value is shown in the upper
display, and the numeric value in the lower display.
7
TPNT
Pulse MIG teach point (0-4, 15
program dependent)
IPM
Wire speed value of Pulse MIG
teach point
VPK
Peak voltage of Pulse MIG
teach point
ADAP
The Special Teach mode allows teach points to be
accessed and the values changed. To access the
Special Teach mode, press the Program, Setup,
and Arc Control push buttons at the same time.
The displays will show “SPEC TEAC”.
Exit the Special Teach mode by pressing the Program, Setup, and Arc Control push buttons at the
same time.
*Optional Location
Control pendant
Arc Control mode
Control pendant
Arc Control mode
Pulse MIG arc length regulation
mechanism
Adaptive On or Off
APK
Peak current of Pulse MIG
teach point
Control pendant
Arc Control mode
ABK
Background current of Pulse
MIG teach point
Control pendant
Arc Control mode
PPS
Frequency of Pulse MIG teach
point
Control pendant
Arc Control mode
PWMS
Pulse width of Pulse MIG teach
point
Control pendant
Arc Control mode
RAMP
Rate of current rise/fall and
from peak current pulse
Control pendant
Arc Control mode
FLTR
Filter length/time duration used
to collect welding data to export
out analog output channels
(20-200 ms)
V1
Welding voltage to correspond
to minimum output of analog
voltage output channel (100 =
10 volts)
V2
Welding voltage to correspond
to maximum output of analog
voltage output channel (800 =
80 volts)
I1
Welding current to correspond
to minimum output of analog
current output channel (50 = 50
amps)
I2
Welding current to correspond
to maximum output of analog
current output channel (800 =
800 amps)
Wire Feed Speed/Amps Push Button
Press the Wire Feed Speed/Amps push button to
toggle between upper and lower displays. Use the
Adjust control to change values.
Description
4-7. Pulse Welding Terms
1
Apk = Peak Amperage
Increasing Apk increases penetration.
3
Vpk = Peak Voltage
Arc voltage during peak current
phase of the pulse waveform. This
determines arc length during
adaptive pulse welding.
Amps
2
Abk = Background Amperage
Maintains arc between pulses.
1
2
3
4
PPS = Pulses Per Second
Increasing PPS increases travel
speed.
Time
4
PWms = Pulse Width In
Milliseconds
Increasing PWms increases bead
width.
OM-210 540 Page 20
Return To Table Of Contents
4-8. Teach Data Points
Apk = Peak Amperage
Vpk = Peak Voltage
Abk = Background Amperage
PPS = Pulses Per Second
IPM / MPM
PWms = Pulse Width (Milliseconds)
780 / 19.8
750 / 19.1
700 / 17.8
650 / 16.5
600 / 15.2
550 / 14.0
500 / 12.7
450 / 11.4
Example Of A Synergic
Setting For 425 IPM With
All Teach Points Set At 50
IPM (1.3 MPM) Increments
400 / 10.2
350 / 8.9
300 / 7.6
250 / 6.4
200 / 5.1
150 / 3.8
100 / 2.5
50 / 1.3
Apk
Vpk
Abk
PPS
PWms
100
10
10
20
1
180
18
20
55
210
21
30
80
240
24
40
105
2
270
27
50
130
The special teach mode allows the user to
create custom pulse programs. The above
example shows 15 teach points. However,
the actual number of teach points is dependent on the weld process selected. At each
teach point (IPM/MPM), the user can adjust
six parameters to shape the pulse waveform
of the weld output. The six parameters are:
Apk, Vpk, Abk, PPS, PWms and Ramp.
300
30
60
160
330
33
70
185
360
36
80
210
3
370
37
90
235
420
42
100
260
450
45
110
290
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
burn off welding wire at a set wire feed
speed. The graph above shows that as wire
feed speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting synergically).
Return To Table Of Contents
4
480
48
120
315
510
51
130
340
540
54
140
365
565
56
200
400
5
Apk
Vpk
Abk
PPS
PWms
Ramp is the rate at which the amperage
changes between the peak and background
pulse phases. Ramp is measured in units of
amps per millisecond.
OM-210 540 Page 21
4-9. Set Value Mode
Program
Volts
Arc Length
Wire Speed
1
Amps
Process
Wirefeed
Wire Type
Gas Type
Gas
Contactor
Setup
Adjust
Arc Control
4
2
3
The Set Value mode is a troubleshooting tool
that allows certain robot command values to
be manually over-ridden.
1
2
3
4
Setup Push Button
Arc Control Push Button
Adjust Control
Wire Feed Speed/Amps Display Push
Button
Enter the Set Value mode by pressing the
OM-210 540 Page 22
Setup and Arc Control push buttons at the
same time. When in the Set Value mode the
display windows show SET VALU and the
blinking LED’s under the display windows indicate whether Volts, Arc Length, or Wire Speed
can be changed using the Adjust control.
Depending on the defined weld process, either volts (MIG) or arc length (pulse) can be
changed in the top display. Wire speed can be
changed in the bottom display. Press the Wire
Return To Table Of Contents
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 control to change values.
Exit the Set Value mode by pressing the Setup
and Arc Control push buttons at the same
time.
SECTION 5 − SAFETY PRECAUTIONS FOR SERVICING
5-1. Symbol Usage
safety_stm 8/03
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y Marks a special safety message.
. Means “Note”; not safety related.
5-2. Servicing Hazards
Y 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.
Y Only qualified persons should service, test, maintain, and repair this unit.
Y During servicing, keep everybody, especially children, away.
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.
HOT PARTS can cause severe burns.
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 after removal of
input power on inverters.
D
FLYING METAL can injure eyes.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
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 touch hot parts bare handed.
D Allow cooling period before working on welding
gun or torch.
EXPLODING PARTS can cause injury.
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.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
MOVING PARTS can cause injury.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
Return To Table Of Contents
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
OM-210 540 Page 23
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
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.
OVERUSE can cause OVERHEATING.
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.
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.
5-3. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
5-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-210 540 Page 24
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Return To Table Of Contents
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Clean And
Tighten
Weld
Terminals
Replace
Damaged Or
Unreadable
Labels
Replace Damaged
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
6-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
803 244-B
Return To Table Of Contents
OM-210 540 Page 25
6-3. Front Panel Error Messages
A number of error messages can be displayed
on the upper and lower displays. The error
messages are defined below.
1 ERR SENS
Indicates the signal from the secondary output
terminals (the machine output studs) is not being detected.
2 UNIT MEM
Indicates a general memory fault.
3 UIM MEM
Indicates a user interface memory fault.
4 ROBT MEM
Indicates a robot input/output control board
memory fault.
5 MOTR MEM
Indicates a motor control board memory fault.
6 ERR TACH
Indicates an error related to the tachometer for
the motor control board.
7 ERR MOTR
Indicates a motor overcurrent fault.
8 ERR WFS
Indicates wire feed speed fault.
9 ERR STRT
Indicates an ArcStart fault.
OM-210 540 Page 26
10 ERR STOP
Indicates an arc stop fault.
11 ERR FLOW
Indicates gas flow is not detected.
12 ERR COOL
Indicates coolant flow is not being detected.
13 WELD WAIT
Indicates a fault condition exists relating to
waiting for the robot to reset the start command.
14 ERR FTP
Indicates an internal communication fault.
15 ERR GND
Indicates current has been detected on the
ground circuit.
16 ERR STUK
Indicates the wire is stuck and a stuck check
could not clear it.
17 ERR PSF
Indicates a fault in the primary power conversion circuit.
18 ERR TEMP
Indicates a temperature shutdown in the power conversion circuitry.
19 ERR LINE
Indicates the primary line voltage is out of
range (above or below unit limits).
Return To Table Of Contents
20 ERR ARC
Indicates the arc went out during the weld process.
21 MOTR COM
Indicates a loss of communication with the
motor control board.
22 ROBT COMM
Indicates a loss of communication with the robot input/output board.
23 PLS WAIT
Indicates a loss of communication with the
user interface board.
24 ERR POS
Indicates the secondary connections for the
motor are incorrectly connected for the desired process.
25 E STOP
Indicates the emergency stop circuitry has
been activated.
26 OVER CRNT
Indicates an over-current shutdown in the
power conversion circuitry.
27 ERR UNKN
Indicates an error has been detected that cannot be decoded by the user interface.
6-4. Removing Cover and Measuring Input Capacitor Voltage
Y Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage on all three
inverter assemblies as shown to be sure the input
capacitors have discharged before working on unit.
Tools Needed:
5/16 in
Turn Off welding power source, and
disconnect input power.
Remove cover
1
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 all three inverter assemblies before proceeding.
Proceed with job inside unit. Reinstall cover when finished.
1
2
+ lead to left bus terminal, − lead to right bus terminal
1
2
+ lead to left bus terminal, − lead to right bus terminal
802 985 / Ref. 803 250-C
Return To Table Of Contents
OM-210 540 Page 27
6-5. Weld Process Board PC4 Diagnostic LED’s
1
Weld Process Board PC4
Diagnostic LED’s are visible inside unit,
located on PC4 mounted on the top tray.
Refer to Section 6-6 for information on
diagnostic LED’s.
1
Reinstall cover after checking diagnostic
LED’s.
LED1
LED2
LED3
LED4
199 375 / Ref. 803 250-C
6-6. Diagnostic LED’s On Process Board PC4
LED
Status
1
On
Indicates −25 volts dc is present on process board PC4
Off
Indicates −25 volts dc is not present on process board PC4
On
Indicates +25 volts dc is present on process board PC4
Off
Indicates +25 volts dc is not present on process board PC4
On
See Network Status Table in Section 6-13
Off
See Network Status Table in Section 6-13
2
3,4
OM-210 540 Page 28
Diagnosis
Return To Table Of Contents
6-7. Motor Board PC6 Diagnostic LED’s And Dip Switch Settings
1
2
Motor Board PC5
Diagnostic LED’s are visible inside
unit, located on PC5 mounted on
the top tray assembly.
Refer to Section 6-8 for information
on diagnostic LED’s.
Reinstall top cover after checking
diagnostic LED’s.
1
LED1
LED1
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
194 368 / 803 251-B
6-8. Diagnostic LED’s On Motor Board PC6
LED
Status
1
On
Indicates +15 volts dc is present on motor board PC5
Off
Indicates +15 volts dc is not present on motor board PC5
On
Indicates +5 volts dc is present on motor board PC5
Off
Indicates +5 volts dc is not present on motor board PC5
On
See Network Status Table in Section 6-13
Off
See Network Status Table in Section 6-13
2
3,4
Diagnosis
Return To Table Of Contents
OM-210 540 Page 29
6-9. Display Module PC7 Diagnostic LED’s
LED1
2
LED2
3
1
803 251-B / 200 416
1 Display Module PC7
Diagnostic LED’s are visible inside unit, located on PC7 mounted behind the front
panel.
Refer to Section 6-10 for information on
diagnostic LED’s.
Reinstall cover after checking diagnostic
LED’s.
2
Dip Switch S1
3
Dip Switch S2
6-10. Diagnostic LED’s On Display Module PC7
LED
Status
1, 2
On
See Network Status Table in Section 6-13
Off
See Network Status Table in Section 6-13
OM-210 540 Page 30
Diagnosis
Return To Table Of Contents
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.
6-11. Automation Module PC9 Diagnostic LED’s
1
LED11
LED13 LED25
LED28
LED12
LED14
LED27
LED31
LED30
2
LED1
LED2
LED3
LED4
3
LED5
LED6
LED7
LED8
LED9
LED33
LED10
LED32
LED15
LED20 LED19 LED18 LED16
LED17
LED21 LED22 LED23 LED24 LED26 LED29
199 377 / Ref. 803 250-C
1 Automation Module PC9
Diagnostic LED’s are visible inside unit, located on PC9 mounted on left side.
Refer to Section 6-10 for information on
diagnostic LED’s.
Reinstall cover after checking diagnostic
LED’s.
2
Dip Switch S3
3
Dip Switch S4
Return To Table Of Contents
Dip switches are used to identify each circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.
OM-210 540 Page 31
6-12. Diagnostic LED’s On Automation Module PC9
LED
Status
1
On
Input signal On from robot for jog advance
Off
Input signal Off from robot for no jog advance
On
Input signal On from robot to energize contactor
Off
Input signal Off from robot to not energize contactor
3
On
Input signal On remote program A selected
Off
Input signal Off remote program A not selected
4
On
Input signal On remote program C selected
Off
Input signal Off remote program C not selected
On
Input signal On from robot for jog retract
Off
Input signal Off from robot for no jog retract
12
On
Input signal On from robot for purge
Off
Input signal Off from robot for no purge
13
On
Input signal On remote program B selected
Off
Input signal Off remote program B not selected
On
Not assigned
Off
Not assigned
On
Input signal On from robot for no emergency stop
Off
Input signal Off from robot for emergency stop
On
Input signal On from relay K2
Off
Input signal Off from relay K2
On
Input signal On from relay K3 for welding power source ready and no detected errors present
Off
Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is
in operating mode preventing the weld ready signal from being enabled
On
Input signal On from relay K4 to indicated wire stuck in weld joint
Off
Input signal Off from relay K4 to indicate wire is not stuck in weld joint
On
Indicates +5 volts dc is present on automation module PC9
Off
Indicates +5 volts dc is not present on automation module PC9
On
Input signal on from relay K5 for flow (shielding gas or coolant) present
Off
Input signal off from relay K5 for flow (shielding gas or coolant) not present
On
Indicates −15 volts dc is present on automation module PC9
Off
Indicates −15 volts dc is not present on automation module PC9
On
Indicates +15 volts dc is present on automation module PC9
Off
Indicates +15 volts dc is not present on automation module PC9
On
Input signal on from relay K6 for arc detected
Off
Input signal off from relay K6 for no arc detected
30, 31
On
See Network Status Table in Section 6-13
Off
See Network Status Table in Section 6-13
32
On
Input signal on for aux. relay energized
Off
Input signal off for aux. relay energized
On
Input signal on touch sensor touch detected
Off
Input signal off touch sensor touch not detected
2
11
5 thru 10,
14 thru 20
21
22
23
24
25
26
27
28
29
33
OM-210 540 Page 32
Diagnosis
Return To Table Of Contents
6-13. Network Status Table
Circuit boards PC4, PC6, PC7, and PC9 have two bi-color (green/red) LED’s to give information about communication
between circuit boards. See the table below for an explanation of what the LED’s indicate.
Status
Off
Green
Flashing Green
Flashing Red
Diagnosis
There is no power applied to the circuit board or the board software is not executing.
The circuit board is operating normally.
The circuit board is in a communication standby mode. Wait or cycle power to clear standby mode.
The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.
Circuit board is unable to communicate with circuit board PC4.
Red
Flashing RedGreen
The circuit board has encountered an unrecoverable fault. Verify dip switch positions according to Sections 6-5. Replace circuit
board if necessary.
The circuit board is performing a communication self-test.
Return To Table Of Contents
OM-210 540 Page 33
6-14. 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
length trim are the same on the control
pendant as on the power source.
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.
Turn unit On. Unit displays abbreviated name of robot
detected. ABB is shown in this example.
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
you wish to stop the calibration
procedure, turn unit input power
off and then on again.
Press Wire Speed/Amps Display push button 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).
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
When the robot calibration mode ends, the ROBT CAL message
stops and the unit will display normal front panel information.
OM-210 540 Page 34
Return To Table Of Contents
198 993
6-15. Robot Reset Mode
RST
NO
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
The reset mode should be used if the
unit goes off-line at 15-20 second
intervals and displays the PLS WAIT
message at each interval.
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
YES
Rotate Adjust knob to change NO
to YES.
RST
YES
CYCL
PWR
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 and back on again to
complete the reset operation.
During the reset mode the following
programs are loaded into the unit:
Program 1
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
Mig
.035 Mild Steel
75% Argon, 25% CO2
Program 3
Accu Pulse
.035 Mild Steel
90% Argon, 10% O2
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
Mig
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
Mig
.052 Mild Steel
75% Argon, 25% CO2
198 993 / 803 246-B
Return To Table Of Contents
OM-210 540 Page 35
6-16. Troubleshooting
Trouble
No weld output; completely inoperative
Remedy
Place line disconnect in On position (see Section 3-12).
Check and replace line fuse(s), if necessary, or reset circuit breaker
(see Section 3-12).
Check for proper input power connections (see Section 3-12).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 3-9).
errors displayed.
Clean and tighten all weld connections.
No 115 volts AC at the duplex
receptacle.
Reset circuit breaker CB1.
Wire does not feed.
Check circuit breaker CB2 and reset if necessary.
Check motor control cable connections.
Wire feeds erratically.
Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Gas does not flow or does not stop flow- Check gas valve and flow meter.
ing; wire feeds.
OM-210 540 Page 36
Return To Table Of Contents
Notes
Return To Table Of Contents
OM-210 540 Page 37
SECTION 7 − ELECTRICAL DIAGRAMS
Figure 7-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)
OM-210 540 Page 38
Return To Table Of Contents
207 903-D (Part 1 Of 2)
Return To Table Of Contents
OM-210 540 Page 39
Figure 7-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)
OM-210 540 Page 40
Return To Table Of Contents
207 903-D (Part 2 Of 2)
Return To Table Of Contents
OM-210 540 Page 41
SECTION 8 − PARTS LIST
. Hardware is
common and
not available unless listed.
2
1
3
4 − Fig 8-3
5 − Fig 8-2
7 − Fig 8-4
6
9
5
16 − Fig 8-5
10
15
8
11
12
14
13
9
15
803 247-C
Figure 8-1. Main Assembly
OM-210 540 Page 42
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . 1 . . . . . T2 . . . . . . . 212543
. . . 2 . . . . . . . . . . . . . . . . 210492
. . . 3 . . . . . . . . . . . . . . . . 210481
. . . 4 . . . . . . . . . . . . . . . . . Fig 8-3
. . . 5 . . IM1, IM2 . . . . 214597
. . . . . . . . . . . . . . . . . . . . . . 214599
. . . 6 . . . . . . . . . . . . . . . . 198961
. . . 7 . . . . . . . . . . . . . . . . . Fig 8-4
. . . 8 . . . . . . . . . . . . . . . . 207898
. . . 9 . . . . . . . . . . . . . . . . 210482
. . . 10 . . . . . W1 . . . . . . . 180270
. . . 11 . . . . . . . . . . . . . . . . 213386
. . . 12 . . . . HD2 . . . . . . 182918
. . . 13 . . . . . . . . . . . . . . . . 198951
. . . 14 . . . . . . . . . . . . . . . . 148025
. . . 15 . . . . . . . . . . . . . . . . 213372
. . . 16 . . . . . . . . . . . . . . . . . Fig 8-5
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, LH w/Components (Fig 8-2) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (Fig 8-2) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Module Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side (LH & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Contactor, DEF PRP 40A 3P 24VAC Coil W/Boxlug . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
14
15
16
. Hardware is
2
common and
not available unless listed.
1
3
4
5
13
6
12
7
11
8
9
36
10
6
37
38
7
18
17
19
20
35
34
21 22
33
32
24
26
25
27
25
29
31
39
30
28
23
24
41
40
802 955-A
Figure 8-2. Windtunnel Assembly LH And RH
Return To Table Of Contents
OM-210 540 Page 43
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Windtunnel Assembly LH And RH (Fig 8-1 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 . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . .
......................
......................
. . . . . . . . . . CT1 . . . . . .
. . . 21 . . . . . . . . . . . . . . . .
. . . 22 . . . C1, C2 . . . . .
. . . 23 . . . . . . . . . . . . . . . .
. . . 24 . . . MOD1 . . . . .
. . . 25 . . . MOD2 . . . . .
. . . 26 . . RT1, RT2 . . . .
. . . 27 . . . . PC2 . . . . . .
. . . 28 . . . . . C3 . . . . . . .
. . . 29 . . . . . . . . . . . . . . . .
. . . 30 . . . . HD1 . . . . . .
......................
. . . 32 . . . R1, R2 . . . . .
......................
. . . 33 . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . . .
. . . 37 . . . . . L2 . . . . . . .
. . . 38 . . . . . . . . . . . . . . . .
......................
......................
. . . 39 . . . . PC1 . . . . . .
. . . 40 . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . . .
214597
196351
213940
214519
196518
199840
201531
196347
196349
203408
196359
170647
179276
196355
010546
047838
146112
214599
196332
153403
196259
115092
115091
196231
201695
203912
210507
201533
201534
214015
201617
196143
196378
182918
196384
196343
196840
109056
196514
196512
196330
196345
196588
196365
199136
214523
196340
083147
. . . 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 . . . . . . . . . . . . . . . . . . .
. . . . Blank, Snap−in Nyl 1.000 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . .
. . . . Blank, Snap-in Nyl .218 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Elctlt 2400 Uf 500 VDC Can 2.5 Dia . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Inverter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Input/Pre−regulator 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 . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
2
4
6
1
1
2
1
1
2
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
4
4
+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-210 540 Page 44
Return To Table Of Contents
. Hardware is
1
common and
not available unless listed.
2
3
4
5
11
6
10
7
9
8
802 916-B
Figure 8-3. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Top Tray Assembly (Fig 8-1 Item 4)
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
. . . . PC12 . . . . . .
. . . . PC3 . . . . . .
................
................
................
. . . . PC9 . . . . . .
................
................
................
................
. . . . PC6 . . . . . .
209676
213555
210490
134201
083147
204048
170647
210491
204838
198122
209681
. . . 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 . . . . . . . . . . . . .
. . . Circuit Card Assy, Micro/Robot/Devicenet . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Tray, Mtg PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Micro/Motor/Devicenet . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
24
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Return To Table Of Contents
OM-210 540 Page 45
. Hardware is
common and
not available unless listed.
8
5
6
9
7
4
2
3
1
10
11
14
12
13
803 248-C
Figure 8-4. Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-4. Rear Panel Assembly (Fig 8-1 Item 8)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
. . . . PC9 . . . . . .
................
. . . . PC10 . . . . . .
................
................
................
................
................
................
................
. . . . CB1 . . . . . .
. . . . CB2 . . . . . .
. . . . PC11 . . . . . .
. . . . RC2 . . . . . .
209684
199297
208319
199295
175282
207894
210358
198996
201058
210483
083432
093995
200570
604176
. . . Circuit Card Assy, Robot Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 6-32 & no 8-32 x 2.50 lg .312 hex alm/m . . . . . . . . . . . . .
. . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 8-32 x .500 lg .312 hex al m&f . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Breaker, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . .
. . . Circuit Breaker, Man Reset 1P 15A 250VAC Frict . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Motor Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
4
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-210 540 Page 46
Return To Table Of Contents
. Hardware is
common and
not available unless listed.
4
2
1
7
6
5
27
11
10
3
25
26
24
9
10
8
23
17
11
10
16
15
12
13
22
18
14
12
19
21
20
803 249-C
Figure 8-5. Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-5. Front Panel Assembly (Fig 8-1 Item 14)
. . . 1 . . . . . S1 . . . . . . .
... 2 ................
... 3 ................
... 4 ................
......................
... 5 ................
... 6 ................
. . . 7 . . . . PC7 . . . . . .
......................
......................
. . . 8 . . . . . FM . . . . . . .
. . . 9 . . . . PC13 . . . . . .
. . . 10 . C6, C7, C8 . . .
. . . 11 . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . .
207456
207895
179851
204393
204394
200410
213887
204049
200416
199376
196313
208071
206878
213102
025248
. . . 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 (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, PC Card Switch/Overlay (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Nameplate, Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cricuit Card Assy, Display/Micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Circuit Card Assy, Micro/User Interface/Devicenet . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy,ISO/COM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . .
Return To Table Of Contents
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OM-210 540 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figue 8-5. Front Panel Assembly (Fig 8-1 Item 14) (Continued)
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...
...
...
...
...
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...
...
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...
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14
15
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22
23
24
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27
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................
. . . . RC5 . . . . . .
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................
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PB1, PB2, PB3 . .
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207897
210866
214664
216966
216965
215467
207896
180732
179848
199443
207902
210865
207893
210483
210358
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . .
. . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Negative Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Positive Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
2
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+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-210 540 Page 48
Return To Table Of Contents
Notes
Notes
Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Your distributor also gives
you ...
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
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.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
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 8/03
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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2004 Miller Electric Mfg. Co.
1/03
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