Miller AXCESS DUAL WIRE FEEDER User manual

Miller AXCESS DUAL WIRE FEEDER User manual
OM-222 394Q
2013−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
R
Axcess Dual
Wire Feeder
Visit our website at
www.MillerWelds.com/ams
File: Advanced Manufacturing Systems
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. 9-Pin Network Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Power Source Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Dual Schedule Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Left/Right Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Front Panel Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Feeder Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Adjust Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Process Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Error Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-222 394 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-222 394 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
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 Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
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 Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D
D
D
D
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-222 394 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-222 394 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2011−10
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
OM-222 394 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-222 394 Page 6
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
procédé de soudage, les manipuler avec
précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-222 394 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer
des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
OM-222 394 Page 8
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-222 394 Page 9
OM-222 394 Page 10
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
OM-222 394 Page 11
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-222 394 Page 12
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
Output
X
Amperes
V
Direct Current
(DC)
Volts
IP
Degree Of
Protection
Duty Cycle
Wire Feed
Percent
Input
Cold Jog (Inch)
Towards
Workpiece
Purge By Gas
Fast
Constant Current
Circuit Breaker
Constant Voltage
Slow
Trigger Hold Off
Trigger Hold On
Rated Welding
Current
Increase
Conventional Load
Voltage
Locked
Read Instructions
I1
A
U1
Primary Voltage
I2
U2
Primary Current
Sequence
Program
Process
Wire Type
Gas Type
Variable
Inductance
Time
Arc Control
Trigger Control
Single Phase
Three Phase
Trigger Hold On
Indicator Light
Trigger Hold
Off Indicator Light
Line Connection
Notes
OM-222 394 Page 13
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications
Type of Input
Power
Welding Power
Source Type
40 Volts DC
10 Amperes
Axcess Series
Wire Feed Speed Range
Wire Diameter
Range
Welding Circuit
Rating
Overall
Dimensions
Weight
Standard: 40 To 1400 ipm (1.0
To 35.6 mpm)
.030 To 1/8 in.
(0.8 To 3.2 mm)
100 Volts,
750 Amperes,
100% Duty
Cycle
Length: 27 in. (686
mm)
87 lb
(39.5 kg)
Max Spool
Weight: 60 lb (27
kg)
Width: 12-1/2 in.
(318 mm)
Height: 14-1/2 in.
(368 mm)
4-3. Environmental Specifications
IP Rating
IP23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
Tipping
!
Do not move or operate
unit where it could tip.
2
OR
1
Location
!
Special installation may be required where gasoline or volatile
liquids are present − see NEC Article 511 or CEC Section 20.
3
!
Do not stack units. Beware of
tipping.
1
Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side
of unit.
2
Hand Cart
Use cart or similar device to move
unit.
3
18 in.
(460 mm)
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_2 3/96 - 804 018-A
OM-222 394 Page 14
5-2. Connection Diagram
1
2
3
4
5
6
7
8
3
Welding Power Source
Wire Feeder
Gas Cylinder
Gas Hose
Network Feeder Cable
Negative (−) Weld Cable
Workpiece
Voltage Sensing Lead
Recommended for Accu-pulse and
RMD (optional).
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
9
Positive (+) Weld Cable
4
5
2
1
9
7
6
8
804 019-A
OM-222 394 Page 15
5-3. Rear Panel Connections And Rotating Drive Assembly
1
2
3
Tools Needed:
9/16, 5/8 in.
Requires fitting with 5/8-18 righthand threads. Connect customersupplied gas hose.
3
1
9-Pin Network Receptacle
Power Switch
Shielding Gas Valve Fitting
(Left And Right)
4
5
6
7
8
2
9
9
Weld Cable Terminal
Jumper Cable
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob (Left And Right)
Rating Label Location
To rotate the drive assembly,
loosen drive assembly rotation
knob, rotate drive assembly, and
tighten knob.
4
5
6
7
8
804 020-A / 802 825-A
5-4. 9-Pin Network Receptacle Information
9
F
E
G
H
I
D
C
A
B
OM-222 394 Page 16
Pin
Pin Information
A
Capacitor C1 to ground
B
Shield
C
Volt sense
D
Can low
E
Can high
F
+24 volts dc common
G
+ 24 volts dc
H
Motor voltage +40 volts dc common
I
Motor voltage +40 volts dc
5-5. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Adjust
Rear
Rolls
Pressure
Indicator
Scale
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Drive Rolls
Tools Needed:
3/16, 5/64 in
Gun Cable
15/16, 3/8 in
End Of Liner
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
liner for the welding wire size. When
installing
gun,
position
liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Once wire
has reached the liner, auto-thread wire by
momentarily pressing Purge and quickly
pressing Jog to begin auto-threading wire.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If contact tip is completely blocked, wire should
slip at the feeder (see pressure adjustment above).Cut wire off. Close cover.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A
OM-222 394 Page 17
5-6. Power Source Display At Power Up
1
2
1
Program
Volts
Time
WFS
Amps
Arc Length
Arc Ctl
Process
Sequence
Wire Type
Gas Type
Trigger Hold
Process Set Up
Power Source
Axcess
Upper Display
Lower Display
2
Trigger Control
Adjust
Feeder Set Up
Upper Display
Lower Display
Net
Wait
DTEC
OFF
Axcs
300/450/675
Voltage Range
10
44
5-7. Dual Schedule Switch Option
1
Maint 2P (Maintained-Contact
2-Pole Switch)
DSS-9M Part# 041 793
OM-222 394 Page 18
1
DSS-9M 1
2
2
A
3
B
4
1
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:
General Terms:
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases
the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by
volts in MIG programs.
Trigger Control
Selecting Trigger Control allows activating trigger functions such as DS, TH, 4T, TDS, and TPS.
DS (Dual Schedule)
Dual Schedule allows selecting a pair of programs that can be used together.
TH (Trigger Hold)
Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger
hold mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed
again.
4T
4T allows the operator to select between weld parameters and crater parameters using the gun
trigger. Crater time must be set for at least 0.2 seconds to make this function operational. If gun
trigger is released during welding, unit goes into trigger hold, then pressing and holding trigger again
causes unit to stay in crater until trigger is released and crater parameter times out.
TDS (Trigger Dual Schedule)
TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS
mode, momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected
weld programs.
TPS (Trigger Program Schedule)
TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily
pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total
of 8 programs.
Program
Eight active slots for selection of various processes, wire type, and parameters.
Process
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
MIG
CV weld process with individual settings of voltage and wire speed.
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as
factory taught data. Adaptive method is controlled by frequency adjustment.
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and
backgrounds. Adaptive response is controlled by peak and minimum current levels. Benefits are
shorter arc lengths, better puddle control, more tolerant of tip-to-work variation, less audible noise, no
arc wandering, allows weld to fill in at toes increasing travel speed and deposition, and more tolerant
to poor fit up and gaps.
Accuspeed (optional)
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed to be tight and fast. Front panel display is ACCU − SPED.
AccuCurve
CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
RMD (optional)
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of
RMD are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat
input into workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge
materials.
Wire Type
Selection of wire type by alloys and classification.
Gas Type
Selection of shielding gas being used in application.
Process Set Up
Selection procedure for entering program.
Program Load
Enters selected program information into program slot.
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of
weld.
Time
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in
the Arc On and Analog input or the Arc On and No Analog input modes).
Arc Length
Distance from end of wire electrode to workpiece.
WFS
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage
setting. In pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power
level on wire electrode (one knob control).
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control
Allows setting of inductance in MIG mode. In pulse and Accu-pulse mode, this adjustment changes
the arc cone by adjusting the preprogrammed factory pulse data. In RMD (optional), this control will
affect the in much the same way as inductance.
OM-222 394 Page 19
General Terms:
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit
transfers per second (provided no other changes are made) and increase the arc-on time. The
increased arc-on time makes the welding puddle more fluid.
Adjust
Control knob used to change or set parameters and functions.
Sequence
Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters.
Preflow
Setting a time value for gas flow prior to arc start.
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only
adjustable with the optional PDA with File Management/WaveWriter software).
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.
Postflow
Setting a time value for gas flow after arc end.
Feeder Set Up
Allow selection of Sequence and trigger functions.
Auto Thread
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously
will automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be
changed using a PDA with File Management/WaveWriter software). Pressing jog, purge, or trigger
switch will terminate the auto-threading feature.
Notes
OM-222 394 Page 20
6-2. Power Switch
1
Power Switch
1
804 021-A
6-3. Left/Right Select Switch
1
Left/Right Select Switch
Pressing the Left/Right Select
switch allows the operator to
choose which side of the units’ controls will operate.
. Depressing the Left or Right
Gun Trigger also allows the
operator to enable the controls on that side of the unit.
1
804 022-A
OM-222 394 Page 21
6-4. Jog/Purge
1
2
3
Jog/Purge Push Button
Gun Trigger Receptacle
Adjust Knob
3
2
804 022-A
1
The Jog/Purge switch provides the following
functions:
 Pressing left side of the Jog/Purge switch
allows the operator to feed wire without
energizing the weld power or gas valve
circuit. The wire will feed at a 60 ipm rate for
3 seconds, then the rate ramps up to 700
ipm until the Jog switch is released.
 The unit also provides the ability to jog the
wire feeder by means of the gun trigger.
When the gun trigger is pressed without
starting an arc, the wire will feed at run-in
speed for the first 3 seconds. During this
time OCV (open circuit voltage) will be pres-
OM-222 394 Page 22
ent as indicated on feeder upper display. After 3 seconds the weld output turns off and
the wire will feed at 60 ipm for the next 3 seconds and then ramps up to 700 ipm until trigger is released or 30 seconds elapses. If the
gun trigger is still activated after 30
seconds, the jog operation is terminated to
prevent complete unspooling of the wire and
an “ERR STRT” message is displayed on
the upper and lower displays. Releasing
and pressing the trigger again will clear the
error.
. If Start Error is enabled using an optional
PDA with File Management/WaveWriter
software, an “ERR STRT” will occur after
the first 3 seconds of run in and jogging
from the trigger is not possible.
 Pressing right side of the Jog/Purge switch
allows the operator to purge gas lines before
welding and to preset gas pressure at the
regulator.
 This unit is equipped with Auto Thread
capability. By rocking the switch from purge
to jog within 0.5 seconds will automatically
feed wire for a factory default setting of 192
in (4877 mm) of wire before stopping. The
default feed rate is 700 ipm. These settings
can be changed using an optional PDA with
File Management/WaveWriter software.
6-5. Front Panel Sections
See
Section
6-7
See
Section
6-6
Program
Volts
Time
WFS
Amps
See
Section
6-8
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Trigger Control
Gas Type
Trigger Hold
Process Set Up
See
Section
6-11
Adjust
See
Section
6-10
Feeder Set Up
See
Section
6-9
OM-222 394 Page 23
6-6. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
3
Program Push Button
Program Push Button LED
The LED lights to indicate that
programs can be changed using
the Adjust knob.
1
Program
Momentarily press button to
illuminate LED. To change the
program number, rotate Adjust knob
to select one of eight programs.
3
Pressing and holding the push
button will display the program
name, current wire size, wire type,
and process.
2
To retrieve the original eight factory
default programs, press and hold
button in on power up. Top display
will show RST, bottom display will
show NO, and Feeder Set Up
button LED will be flashing. Turn
Adjust control to change bottom
display to show YES, then press
Feeder Set Up button to confirm
selection. Continue by allowing
feeder to proceed with power up.
6-7. Upper Display
3
1
2
4
Volts
Arc Adjust
5
1
Upper Display
The upper display at idle (not welding) shows
preset volts with process selection MIG or Arc
Adjust for all other processes. When welding,
the display shows actual voltage. The display
will show actual voltage for approximately 3
seconds after welding stops before returning
to preset value.
2
Upper Display Push Button
Press the button to illuminate the LED and
allow changing information in the display.
3
Upper Display Push Button LED
The upper
display
OM-222 394 Page 24
push
button
LED
illuminates to indicate that information
displayed can be changed by the Adjust knob.
4 Volts LED
Indicates a voltage value is being displayed,
preset voltage in MIG when not welding and
actual voltage while welding.
5 Arc Adjust LED
Indicates that displayed value is an arc length
value when the process is Pulse, Accu-pulse,
or RMD (optional).
. At any
time while welding, the display
allows adjustment of the weld voltage or
arc adjust preset values by turning the
Adjust knob. The preset values will be
displayed while the knob is being rotated
and return to displaying actual values
when adjustment is completed.
To activate Carbon Arc Gouging (CAC), press
and hold the upper display push button in on
power up. CAC will appear on the upper display and NO will appear on the lower display.
Rotate adjust knob to YES on the lower display, and press the flashing Feeder Set up
push button . CYCL will appear on the upper
display and PWR will appear on the lower display. Turn welding power source off and back
on again to enable the Carbon Arc Gouging
process selection.
6-8. Lower Display
5
7
Time
1
6
2
WFS
Amps
Arc Ctl
3
1
Lower Display
The lower display shows WFS (wire feed
speed), AMPS (amperage), ARC CTL (arc
control), or Time. The feeder displays only
preset wire speed at idle (not welding). While
welding, the average amperage is displayed.
The lower display shows welding sequence
time when the Time LED is illuminated.
2
WFS (Wire Feed Speed) LED
LED illuminates to indicate the preset wire feed
value is being displayed and can be adjusted
using the Adjust knob.
3
Amps LED
LED illuminates to indicate the average
amperage is being displayed while welding
and for 3 seconds after welding is terminated.
The amperage must be above a minimum
value of 25 amps for this function to operate.
4
4 Arc Ctl (Arc Control) LED
LED illuminates to indicate that inductance
(MIG) or ARC [Pulse, Accu-pulse, or RMD
(optional)] is being displayed and can be adjusted using the Adjust knob.
5 Time LED
LED illuminates to indicate that a time value is
being displayed for a sequence function and
can be adjusted using the Adjust knob.
6 Lower Display Push Button
7 Lower Display Push Button LED
Pressing the button illuminates the LED and
selects either WFS or Arc Ctl value for
changing using the Adjust knob.
To select Arc Ctl, press and hold lower display
button for 2 seconds. The top display will show
either INDU for a MIG program or ARC for
Pulse, Accu-pulse, or RMD (optional). To exit
Arc Ctl or INDU, either press the upper display
push button or press and hold the lower display
push button for 2 seconds.
When the lower display push-button LED and
the WFS LED are both illuminated, it is
possible to change WFS while welding by
using the Adjust knob. The value in the display
will switch momentarily to show preset wire
feed speed while turning the Adjust knob and
revert back to actual value when adjustment is
completed.
When the Arc Ctl LED is illuminated, it is possible to change values while welding by using
the Adjust knob. To return to actual values on
the display, exit the Arc Ctl display.
. The lower display push button has addi-
tional functions when entering the sequence and trigger control functions (see
Section 6-9).
OM-222 394 Page 25
6-9. Feeder Set Up Push Button
3
4
Start
Time
Sequence
Trigger Control
Trigger Hold
Preflow
Time
1
2
Crater
Time
Postflow
Time
5
Sequence Diagram
Feeder Set Up
1 Feeder Set Up Push Button LED
2 Feeder Set Up Push Button
 Press button to choose Sequence. Feeder
Set Up push-button LED will illuminate.
3 Sequence LED
 When the Feeder Set Up button is pressed
once, the Sequence LED will illuminate and
the upper display will show sequence
options. Use the Adjust knob to select PRE
(preflow), STRT (start), CRTR (crater), or
POST (postflow).
 Press the lower display push button and the
Lower Display push-button LED will
illuminate as well as the lower display. The
Time LED will automatically begin flashing
indicating that a time value can be entered
by turning the Adjust knob. By entering a
time value the sequence state will become
active. To turn off a sequence state, change
the time value to OFF. To step back for
selecting another sequence option, press
the Upper Display push button.
 The Sequence option STRT and CRTR will
have additional parameter settings. By
pushing the Lower Display push button a
second time, while STRT or CRTR appear
in the upper display, allows entering voltage
(MIG) or Arc Adjust [Pulse, Accu-pulse, or
RMD (optional)]. Use the Adjust knob to
change the values indicated by the flashing
LED for either Volts or Arc Adjust. Pressing
the Lower Display push button a third time
will activate the WFS setting for either STRT
or CRTR and the WFS LED will begin flashing. Use the Adjust knob to change the WFS
value.
 Pressing the Feeder Set Up button two
more times will exit the Sequence menu and
return the system to standby mode.
4 Trigger Control LED
 Press the Feeder Set Up button twice and
the Trigger Control LED will illuminate, and
the upper display will show the different trigger control selections. Use the Adjust knob
to cycle through the trigger control methods
as follows: DS, TH, TDS, TPS, and 4T (see
Section 6-1 for definitions). The lower display will show the current state of each trigger control method as being on or off. Not all
trigger control methods are compatible with
each other, therefore, turning on certain trigger selections will cause other trigger selections to turn off.
 Press the lower display push button to illuminate the push-button LED and enable the
use of the Adjust knob to allow turning selected trigger control methods on or off. If
trigger hold is set to on, the Trigger Hold
LED will illuminate.
. Trigger Hold is automatically set to On
with the 4T trigger selection. This is part
of the 4T function.
 Press the Feeder Set Up button a third time
to cycle back to standby mode.
5 Lock LED
 The lock LED is illuminated when one or more
programs have been locked using an optional
PDA with File Management/WaveWriter
software. This indicates that some programs
have been disabled. A disabled program will
not show up for selection.
Refer to the File Management/WaveWriter
Owner’s Manual for additional information.
6-10. Adjust Knob
1
Adjust Knob
The Adjust knob is used to change
functions and parameters. Refer to
the front panel sections for
information regarding use of this
control.
1
Adjust
OM-222 394 Page 26
6-11. Process Set Up Push Button
1
2
3
Process Set Up Push Button
Process Set Up LED
Program Selection LEDs
Process
Wire Type
Gas Type
3
2
1
Process Set Up
 Press the Process Set Up push button the
first time will illuminate the button LED and
the Process LED. The upper and lower
displays will be used for Accu-pulse and
only the lower display for MIG, Pulse and
RMD (optional) to show the current process
installed in this program. To change
process, turn the adjust knob.
 Pressing the Process Set Up push button a
second time will illuminate the Wire Type
LED and the lower display will show wire
types available for selected processes (see
Table 6-1 for wire abbreviation). To make a
selection, turn the Adjust knob.
 Pressing the Process Set Up push button a
third time will keep Wire Type LED lit and the
upper display will show wire alloy type (see
Table 6-1 for alloy types). The upper display
push-button LED will be flashing indicating
that turning the Adjust knob will change the
alloy type for the selected process and wire
type.
 Pressing the Process Set Up push button a
fourth time will keep Wire Type LED lit and
the upper display will show wire size. The
upper display push button will be flashing
indicating that turning the Adjust knob will
select wire sizes available for that particular
process and wire type.
 Pressing the Process Set Up push button a
fifth time will illuminate the Gas Type LED
and the lower display will show GAS and the
upper display will show gas selection (see
Table 6-1 for gas abbreviations). To make a
gas type selection, turn the Adjust knob.
 If any of the Process, wire type, alloy type,
wire size, or gas type was changed, then
pressing the Process Set Up push button a
sixth time will show PROG in the upper
display and LOAD in the lower display. The
new program would be loaded for that
particular program in slot 1 thru 8. If no
changes were made to any setup items, no
program will be loaded, and unit will return
to standby mode.
 If a custom program is loaded using an
optional PDA with File Management/WaveWriter software, the Program Display will
have a “C” in front of the program number.
This indicates that the program is not a
factory default program and has been
modified. By selecting or changing any
process variable and performing a program
load will restore the program back to the
factory default program.
 Pressing and holding the Process Set Up
push button in on power up allows viewing
the software revisions of each circuit board
in the system. The top display shows the
board (PCM, UIM, WFCM, and AIM (automated units only) and the lower display
shows the last 3 digits of the circuit board
part number plus a letter designator. Press
the flashing Feeder Set Up push button to
exit the screen displays and continue the
power up process.
Table 6-1. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2,
98% Argon/2% O2
CO2
C10
C15
C25
C5
OX5
OX2
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2
(81Ar/18HE/1CO2
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO2
MIG/RMD)
OX2
Tri Gas
Cored Tubular Wire
Aluminum
MCOR
ALUM
71, 76, 86R, 409
4XXX, 5XXX
Tri Gas
90% Argon/10% CO2
C10
98% Argon/2% O2
OX2
100% Argon
ARGN
* Not all wire types may be available with your unit.
OM-222 394 Page 27
6-12. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
RST
NO
. System configuration data will be
lost during the Reset operation.
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, wait 10 seconds, and turn
power back on again to complete the reset
operation.
During the reset mode the following
factory default programs are loaded
into the unit:
Program 1
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3
Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
.052 Mild Steel
75% Argon, 25% CO2
. After
Reset is complete, be sure to load
appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation
198 993 / 803 246-B
OM-222 394 Page 28
SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence mode, see Feeder
Set Up Push Button in Section
6-9.
Sequence
Weld Time can only be set by using
an optional PDA with File
Management/WaveWriter software.
Parameters
Volts/Arc
Adjust
Seconds
If time is set to zero in any timed
sequence, the sequence is skipped.
1. Preflow
Off-5.0
. Maximum IPM may actually be
2. Postflow
Off-5.0
IPM
3. Start
10.0-44.0/
0-99
40-1400
Off-5.0
4. Crater
10.0-44.0/
0-99
40-1400
Off-5.0
lower depending on the process
and wire type selection.
Weld
Crater
Time
Preflow
Time
Preflow
Trigger
Pressed
Start
Time
Start
Postflow
Time
Weld
Crater
Postflow
Sequence
End
Trigger
Released
OM-222 394 Page 29
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Disconnect power
before maintaining.
~ Weld Terminals
l Damaged Gas Hose
nl Cords
nl Gun Cables
nl Cracked Parts
OR
~ Drive Rolls
Notes
OM-222 394 Page 30
~ Inside Unit
during severe conditions.
l = Replace
l Unreadable Labels
Every
6
Months
. Maintain more often
Reference
nl Weld Cables
8-2. Error Code Troubleshooting Tables
ERR
Display Example
TACH
. The following error codes may appear on the upper and lower displays of the User Interface Module
to indicate specific errors. Explanations of
the error codes are provided in the sections referenced.
Error Type
User Interface Module
Upper Display
User Interface Module
Lower Display
Reference
Emergency Stop
E
STOP
Section 8-2. A
Arc Error
ERR
ARC
Section 8-2. B
No Coolant Flow
ERR
COOL
Section 8-2. C
Ground Current
Detect Error
ERR
GND
Section 8-2. D
Line Error
ERR
LINE
Section 8-2. E
Motor Over Current
ERR
MOTR
Section 8-2. F
Arc Start Error
ERR
STRT
Section 8-2. G
No Tach Error
ERR
TACH
Section 8-2. H
Thermal Over
Temperature
ERR
TEMP
Section 8-2. I
Unknown Error
ERR
UNKN
Section 8-2. J
Motor Communications Error
MOTR
COMM
Section 8-2. K
Over Average Current
OVER
AVE
Section 8-2. L
Over Current
OVER
CRNT
Section 8-2. M
Release Trigger
REL
TRIG
Section 8-2. N
Trigger Stuck
TRIG
STUK
Section 8-2. O
Wire Feed Speed Error
ERR
WFS
Section 8-2. P
Stop Error
ERR
STOP
Section 8-2. Q
Flow Error
ERR
FLOW
Section 8-2. R
Stuck Error
ERR
STUK
Section 8-2. S
Weld Wait
WELD
WAIT
Section 8-2. T
Please Wait
PLS
WAIT
Section 8-2. U
Low Wire Feed Speed
LOW
WFS
Section 8-2. V
Demo Done
DEMO
DONE
Section 8-2. W
Net Wait
NET
WAIT
Section 8-2. X
Software Error
SW
ERR
Section 8-2. Y
Check Web
CHCK
WEB
Section 8-2. Z
OM-222 394 Page 31
A. Emergency Stop Error
Indicates an emergency stop error.
Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board
PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12.
In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.
E
When relay CR1 on E-Stop board PC12 is de-energized, it drops out the 18 volts AC from transformer T1 that powers the
inverter control board(s).
STOP
When relay CR2 on E-Stop board PC12 is de-energized, it breaks the contactor signal being sent to the inverter engine
board(s) from the process control module PC4 (J2-9 to RC2-3) and causes a loss of signal to the AIM board (RC2-1 and
RC2-2) and to micro input (RC5-3 and RC5-4), signaling an E-Stop is active.
When relay CR3 on E-Stop board PC12 is de-energized, it breaks the secondary side output of the motor board before it
goes to the filter board.
Relay CR4 on E-Stop board PC12 is a soft start relay in parallel with the contacts of relay CR1.
B. Arc Error
ERR
ARC
Indicates voltage has exceeded the programmable limit of a valid arc for the programmed amount of time (default time is
500 ms). Check contact tip, weld conditions, and shielding gas.
Arc error can be enabled or disabled using an optional PDA with File Management/WaveWriter software.
C. No Coolant Flow Error
ERR
COOL
Indicates no coolant flow in water flow switch option. The error may be reset by reestablishing coolant flow to the gun, and
then pressing the Jog/Purge button.
D. Ground Current Detect Error
ERR
GND
Indicates that weld current is flowing through the primary ground. This is a latching error and welding power source power
must be cycled off and back on again.
E. Line Error
ERR
LINE
Indicates that primary power has dropped below the operating point of the welding power source. Signal is sent from inverter engine module(s) (RC6, Pin 9 on inverter control board PC1) to process control module PC4 (J2, Pin 1). Check for a
brown-out condition. The primary boost capacitors have dropped below an acceptable minimum voltage threshold.
This circuit monitors the 940 volts primary DC bus voltage across the electrolytic capacitors C1 and C2. Low line is displayed when this voltage drops below 858 volts DC. This could happen when attempting to draw near rated output power
with an input voltage below 190 volts AC, three phase. This causes the boost section to go into current limit trying to supply the output power. Once current limit is reached, the boost section can no longer hold the bus capacitors at 940 volts
DC. The inverter control will also go into an output current limit mode in an attempt to supply output power.
F. Motor Over Current Error
ERR
MOTR
OM-222 394 Page 32
Indicates that the motor has been drawing too much current for too long a time period. To remedy this fault, reduce the wire
feed speed or the wire feeder torque load/duty cycle. Press Jog/Purge button to clear error.
G. Arc Start Error
ERR
STRT
Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at
least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5
volts). This situation is usually attributed to a contact tip or feeder issue. The arc start error parameter can be disabled
using an optional PDA with File Management/Wave Writer software.
H. No Tach Error
Indicates loss of tachometer feedback. Determine cause of error as follows:
ERR
TACH
I.
S
Press JOG button on the front panel.
S
Does the motor run wide open immediately?
S
YES Replace Motor Board PC6.
S
Does the motor ramp up in speed?
S
YES Bad motor tach. Contact nearest Factory Authorized Service Agent.
S
Does the motor respond at all?
S
YES Contact nearest Factory Authorized Service Agent.
S
Check motor cable. Is it damaged?
S
YES Replace motor cable.
S
NO Contact factory service personnel.
Thermal Over Temperature Error
Indicates one or more of the inverter engines overheated. Sent from inverter engine module(s) (RC6, Pin 12, on inverter
control board PC1) to process control module PC4 (J2, Pin 7). Check fan on inverter engine(s) and weld currents.
This signal is the sum of two conditions: shutdown that comes from the temperature monitoring circuit on the inverter control board, and Pwr-Up-Cnt that generated by the boost section of the inverter control board. When either of these signals
is active, RC6-12 is pulled low (this is the not ready line out of the inverter control board).
Shutdown is active when there is an over-temperature condition on the primary or secondary heatsink or on the boost
inductor. To determine which of the two locations is at fault, check LED 1 and LED 2 on inverter control board PC1.
ERR
TEMP
S
If LED 1 is lit, this indicates an over-temperature condition on the primary heat sink.
S
If LED 2 is lit, this indicates an over-temperature condition on the secondary heat sink or on the boost inductor.
Pwr-Up-Cnt (power up control) monitors primary voltage start-up conditions when the power source is first turned on. This
signal is opto-isolated from the boost section of the inverter control board. The following conditions must be met for the
power source to power up:
S
Auxiliary power board PC3 must be powered up and operating to supply prepower of +15 volts DC to the boost section of inverter control board PC1.
S
The peak voltage of the input line power must be greater than 150 volts peak.
S
The DC bus voltage must be greater than 85% of the rectified line voltage. This bus voltage also turns on the
pre-charge relay.
S
The DC bus voltage must be boosted to greater than 858 volts DC.
If any of these conditions are not met, then receptacle RC6-12 is pulled low and weld output is locked out.
J. Unknown Error
ERR
UNKN
Indicates error bit from process control module PC4 is set, but error value sent does not match anything defined with the
UIM board PC7.
OM-222 394 Page 33
K. Motor Communications Error
The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system
motor cable and secondary cables. Separate cable as much as possible.
Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6.
Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1. If there is no voltage present there, check
for 40 volts DC at J16-1 to J16-2. If voltage is present there and neither LED is lit (Red or Green), try to download WFM
code to welding power source. If neither LED turns on after downloading code and cycling power, replace WFM board
PC6.
If LED3 and LED4 are flashing Red or Green or they are solid Red, this indicates the WFM board is still not communicating
with the PCM board PC4. Be sure that the UIM board PC7 is on-line (two green LEDs lit).
MOTR
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
S
Check process control module PC4 for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
If +24 volts is not present at the connector, proceed as follows:
S
Disconnect connector J10 and J11 from WFM board PC6. Check for +24 volts DC at J10-2 (+) and J10-5 (−), and
J11-2 (+) and J11-5 (−). One of the two connectors must measure +24 volts DC to ensures that the Devicenet lines
are being sent from process control module PC4 to WFM board PC6. If +24 volts DC is present at either connector,
replace WFM board PC6.
S
If +24 volts DC is not present at either J10 or J11 connector, check process control module PC4 at connectors J6, J7,
and J8.Remove plugs from connectors and check for +24 volts DC at pin2 (+) and pin 5 (−). If +24 volts DC is not
present at any of the connectors, replace process control module PC4.
COMM
If LED3 and LED4 are both green this indicates that the WFM board went off-line and then recovered which is usually due
to noise interference.
S
Check wire drive motor isolation. Isolated portion of motor housing should not touch robot arm, welding power source
chassis, lifting eye bolts, or weld secondary common. Measure impedance between chassis and both weld secondary
commons. Measure the impedance across motor isolation barrier on motor housing. All measurements should read
high impedance.
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
L. Over Average Current Error
Output current is exceeding the thermal capabilities of the welding power source for approximately 25 seconds.
Default value is as follows:
Axcess 450 limit is 610 A average
This is a duty cycle error and requires 5 minutes with power on and NO welding to clear the error.
This error indicates that an excessive amount of current was drawn over a short period of time. Over-average current is
drawn for a period of approximately 25 seconds and can also be expressed as exceeding the power source duty cycle.
OVER
AVE
The current limit is as follows:
Axcess 450 is 610 amperes
This alarm cannot be reset. To clear the condition, the power source must be turned on and allowed to idle for approximately 5 minutes. This cooling period is determined by an internal timer, and turn off power will not reset the timer since it is
saved with the Configuration data. After the 5 minute cooling period, press the Jog or Purge button, or cycle power to clear
the alarm.
If this alarm was received by mistake, and the power source did not exceed the duty cycle, check the following:
Check current feedback signal either while welding or connecting to a load bank. Measure between test point TP8 and
grounding strap on process control module PC4. Test point TP8 is located on left-hand side of board, about 1 in. (25 mm)
to the right of connector J11. TP8 is scaled: 1 volt measured equals 100 amperes actual. This measurement should read 0
volts when not welding. If the measurement reads approximately 13 volts DC, disconnect LEM device from engine (one at
a time) to determine if either device is bad. If the voltage reading still does not change, unplug the lower inverter control
board; if the reading remains the same, replace the upper inverter control board. Voltage readings should be present while
welding. If voltage readings are not correct for current feedback scaling, check individual inverter engines.
OM-222 394 Page 34
M. Over Current Error
Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6,
Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6).
OVER
The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip
this circuit, only a fault will cause an over-current condition. LED4 will be lit on the inverter control board, and power must
be cycled to clear this error.
S
The most likely fault to trip this circuit is an open 940 volts DC bus bleeder resistor, either R1 or R8 on the interconnect
board. An open resistor will cause the bus, which is split between two series capacitors, to become unbalanced. The
capacitor with the open resistor will go to approximately 340 volts DC. The other capacitor will go to approximately 600
volts DC. Normally, both capacitors are at approximately 470 volts DC. The unit will weld like this most of the time. A
16 uF balancing capacitor in series with the transformer can keep the transformer from saturating under these adverse
conditions. Occasionally, the inverter transformer will saturate, and when this happens, it draws a huge amount of
current and trips the over-current circuit. This condition locks off the inverter control board and eventually the bus capacitors will fail. A change to a different resistor eliminated this situation and the problem is no longer an issue.
S
A shorted output diode will cause an over-current error and no weld output will be available.
CRNT
N. Release Trigger Error
REL
TRIG
Indicates a timed weld has expired, but the trigger is still active. Press Jog/Purge button to clear error.
This error occurs after a timed weld expires and the trigger is not released. A PDA with File Management/WaveWriter
software can be used to set up timed welds. This is strictly an informational−type error.
O. Trigger Stuck Error
TRIG
STUK
Indicates the welding power source was turned on and the trigger signal attempted to weld. Turn welding power source off
and back on again to clear the error.
This error indicates a trigger source was activated while the power source was being powered up. If the trigger source is
removed, the error can be cleared.
S
Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or
trigger command.
S
If LED2 is lit on RIO board PC10, a contactor signal is being sent from the robot.
P. Wire Feed Speed Error
ERR
WFS
Indicates a wire feed speed error. Press Jog/Purge button to clear error.
This error indicates actual wire feed speed does not match wire feed speed command.
Q. Stop Error
ERR
STOP
Indicates an arc stop error. Press Jog/Purge button to clear error.
This error occurs as a result of obstructions in the wire feed system or a faulty wire drive system. Check wire feed and
wire drive system.
R. Flow Error
ERR
FLOW
Indicates a gas flow error. Press Jog/Purge button to clear error.
This error occurs when there is no gas flow to the gun. Check shielding gas system and reestablish gas flow to the gun.
OM-222 394 Page 35
S. Stuck Error
ERR
STUK
Indicates a wire stuck error. Press Jog/Purge button to clear error.
This error occurs if the welding wire sticks to the workpiece at the end of a weld. This fault may be caused by poor welding
conditions. Cut the welding wire from the workpiece.
T. Weld Wait
WELD
WAIT
Indicates a weld cycle wait error. Press Jog/Purge button to clear error.
This error occurs when the unit is not ready for a weld sequence.
U. Please Wait
PLS
WAIT
Indicates a UIM communication error. Press Jog/Purge button to clear error.
This error occurs when the user interface circuit board loses data communications.
V. Low Wire Feed Speed
LOW
WFS
Indicates a low wire feed speed command error. Press Jog/Purge button to clear error.
This error occurs when actual wire feed speed is lower than the wire feed speed command. Check for obstructions in the
wire feed system or a faulty wire drive system.
W. Demo Done
DEMO
Indicates RMD/Accuspeed demo has expired. Press Jog/Purge button to clear error.
DONE
This message appears when RMD and Accuspeed demos are completed. Pressing the Jog/Purge button will change the
screen to CYCL PWR on the display. Turn unit power off and back on again. RMD and Accuspeed share the same demo
timer. If the time expires for one demo process, both demo processes are deactivated.
X. Net Wait
NET
WAIT
Indicates a communication problem. Press Jog/Purge button to clear error.
If the display remains in NET WAIT status, this indicates there is a communication problem between various circuit boards
in the wire feeder or ROI and welding power source.
Y. Software Error
SW
Indicates incompatible software code. Press Jog/Purge button to clear error.
ERR
This error occurs after a software download and the versions between circuit boards are not compatible or a feeder or ROI
that has not been updated is connected to a power source with incompatible code. This error can also occur if power is
cycled off and on with less than 10 seconds of off time.
Z. Check Web
CHCK
WEB
OM-222 394 Page 36
Indicates an E Module update error. Press Jog/Purge button to clear error.
This error occurs when performing an E Module update to an existing unit. This requires connecting to the web pages to
enter serial number information.
8-3. Troubleshooting
!
Disconnect power before troubleshooting.
Trouble
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check and secure weld cable connections (see Section 5-2).
Electrode wire feeding stops or feeds
erratically during welding.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 5-5).
Change to correct size drive roll (see 5-5).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
Notes
OM-222 394 Page 37
SECTION 9 − ELECTRICAL DIAGRAM
Figure 9-1. Circuit Diagram
OM-222 394 Page 38
218 564--F
OM-222 394 Page 39
SECTION 10 − PARTS LIST
. Hardware is common and
not available unless listed.
6
7
8
5
9
10
11
12
11
10
9
13
14
16
4 − Figure 10-3
17
18
3
15
19
2
1
22
20
21 − Figure 10-2
804 023-A
Figure 10-1. Main Assembly
OM-222 394 Page 40
Item
No.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
17
18
19
20
21
22
. . . . . . . . . . . . . . . 159 647
. . . . . . . . . . . . . . . 159 646
. . . . . . . . . . . . . . . 159 360
. . . . . . . . . . . . Figure 10-3
. . . . . . . . . . . . . . . 143 160
. . . . . . . . . . . . . . . 058 427
. . . . . . . . . . . . . . . 180 573
. . . . . . . . . . . . . . . 010 233
. . . . . . . . . . . . . . . 057 971
. . . . . . . . . . . . . . . 010 191
. . . . . . . . . . . . . . . 058 628
. . . . . . . . . . . . . . . 058 428
. . . . . . . . . . . . . . . 071 730
. . . . . . . . . . . . . . . 135 205
. . . . . . . . . . . . . . . 141 411
. . . . . . . . . . . . . . . 208 339
. . . . . . . . . . . . . . . 208 338
. . . . . . . . . . . . . . . 156 243
. . . . . . . . . . . . . . . 145 639
. . . . . . . . . . . . . . . 139 226
. . . . . . . . . . . . . . . 134 306
. . . . . . . . . . . . Figure 10-2
. . . . . . . . . . . . . . . 220 350
. . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Drive Assembly, Wire S/L 4 Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hub & Spindle Assembly, (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Shaft Assy, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring, Cprsn .970 OD x .120 Wire x 1.250pld . . . . . . . . . . . . . . . . . . .
. . . . Washer, Flat .632 ID x 1.500 OD x .125thk Stl Pld .175 Keyed . . . . .
. . . . Washer, Flat .656 ID x 1.500 OD x .125thk Fbr . . . . . . . . . . . . . . . . . . .
. . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tubing, Stl .875 OD X 12 Ga Wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, .625-11 .94 Hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . .
. . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, w/Extension (LH) Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob. w/Extension (RH) Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strip, Buna N Compressed Sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . .
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Foot, Rubber 1.250 Dia x 1.375 High No 10 Screw . . . . . . . . . . . . . . . . .
. . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Drive Assy, Wire Rt 4 Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
8
1
2
1
1
1
2
2
2
1
1
1
1
1
1
2
2
1
4
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-222 394 Page 41
. Hardware is common and
2
1
not available unless listed.
7
6
9
10
11
12
13
8
3
14
26
15
5
25
16
4
17
24
19
8
18
20
21
22
23
804 024-D
Figure 10-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Control Box (Figure 10-1 Item 21)
. . . 1 . . . . . . . . . . . . . . +220 321
. . . 2 . . . . . . . . . . . . . . . 134 464
. . . 3 . . . . . . . . . . . . . . . 233 581
. . . 4 . . . . PC6 . . . . . 231 109
. . . 5 . . . . . . . . . . . . . . . 134 201
. . . 6 . . . . PC2 . . . . . 212 493
. . . 7 . . . . . . . . . . . . . . . 220 063
. . . 8 . . . . . . . . . . . . . . . 010 494
. . . . . . . . . . . . . . . . . . . . . 220 314
. . . 9 . . . . . . . . . . . . . . . 038 855
. . . 10 . . . . . . . . . . . . . . . 216 696
. . . 11 . . . . . . . . . . . . . . . 224 383
. . . . . . . . . . . . . . . . . . . . . 220 458
. . . 12 . . . . . S1 . . . . . . 213 632
. . . 13 . . . . RC1 . . . . . 211 018
. . . 14 . . . . . . . . . . . . . . . 211 989
. . . 15 . . . . . . . . . . . . . . . 220 805
. . Wrapper, Feeder Dual Axcess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, PC Card Switch/Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Wire Feed Module w/Program . . . . . . . . . . . . . . . . . . .
. . Stand−Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Motor Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap−In Nyl 1.375 ID x 1.750 Mtg Hole . . . . . . . . . . . . . . . . . .
. . Filter Assy, Sense Lead (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Block, Term 20 Amp 2 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, w/Terminals (.027uf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor, w/Terminals (2k 5 Watt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cable, Volt Sense 23 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Rocker Dpdt 10A 250VAC/20A 30VAC On-None-On . . . . . . . . .
. . Connector, Circ 97/Met 9 Pin Size 20 Rcpt . . . . . . . . . . . . . . . . . . . . . . . .
. . Fitting, w/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 750-14 NPS 1.48hex .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
16
2
1
2
2
2
2
2
1
1
1
2
2
+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-222 394 Page 42
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Control Box (Figure 10-1 Item 21) (Continued)
...
...
...
...
...
...
...
...
...
...
...
16
17
18
19
20
21
22
23
24
25
26
...............
...............
...............
...............
...............
...............
...............
. . . . . S2 . . . . . .
...............
...............
. . . . PC1 . . . . .
030 170
228 035
125 473
097 132
220 320
237 937
221 081
200 295
201 641
179 851
212 459
..
..
..
..
..
..
..
..
..
..
..
Bushing, Snap−In Nyl .750 ID x 1.000 Mtg Hole . . . . . . . . . . . . . . . . . . . .
Valve, 34VDC 1way .750−14thd 2mm Orf 100psi . . . . . . . . . . . . . . . . . . .
Hose, SAE .187 ID x .410 OD x 27.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand−Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Rocker SPDT 15A 12V (On)-Off-(On) . . . . . . . . . . . . . . . . . . . . . .
Switch, Rocker SPDT 15A 12V (On)-Off-(On) . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer 1.670 Dia x .250 Id Push On w/Spring . . . . . . . . . . . . . . .
Circuit Card Assy, Trigger Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
8
1
1
1
2 ..
2
1
2
+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-222 394 Page 43
. Hardware is common and
not available unless listed.
11
12
13
14
15
See Table 10-1 For
Drive Roll & Wire Guide Kits
16
17
18
9
2
1
3
4
5
8
7
6
12
19
10
13
33
20
32
31
30
25
35
21
22
23
24
26
29
28
27
34
3
4
5
6
2
1
802 950-C
Figure 10-3. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Drive Assembly, Wire ( Figure 10-1 Item 4)
. . . 1 . . . . . . . . . . . . . . . 010 668
. . . 2 . . . . . . . . . . . . . . . 172 075
. . . 3 . . . . . . . . . . . . . . . 149 962
. . . 4 . . . . . . . . . . . . . . . 149 486
. . . 5 . . . . . . . . . . . . . . . 132 750
. . . 6 . . . . . . . . . . . . . . . 150 520
. . . 7 . . . . . . . . . . . . . . . 133 493
. . . 8 . . . . . . . . . . . . . . . 133 350
. . . 9 . . . . M1 . . . . . *213 005
. . . . . . . . . . . . . . . . . . . . . 203 631
. . . 10 . . . . . . . . . . . . . . . 182 415
. . . 11 . . . . . . . . . . . . . . . 203 640
. . . 12 . . . . . . . . . . . . . . . 133 739
. . . 13 . . . . . . . . . . . . . . . 203 641
. . . 14 . . . . . . . . . . . . . . . 182 156
. . . 15 . . . . . . . . . . . . . . . 182 155
. . . 16 . . . . . . . . . . . . . . . 132 746
. . . 17 . . . . . . . . . . . . . . . 203 633
. . . 18 . . . . . . . . . . . . . . . 203 632
. . . 19 . . . . . . . . . . . . . . . 203 637
. . Screw, Cap Stl Sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Carrier, Drive Roll w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Flat Stl .257 ID x .619 OD x .105 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ring, Retaining Ext .250 Shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pressure Arm (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, w/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Flat Buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . .
. . . . Washer, Flat Stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, w/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
2
2
2
2
1
1
1
1
1
2
2
2
2
2
1
1
1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
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-222 394 Page 44
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Drive Assembly, Wire (Figure 10-1 Item 4) (Continued)
. . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . {Encoder Assy, Quad 500 CPR 5 VDC Shaftless w/Plug (including) . . . 1
. . . . . . . . . . . . . . . . . . . . . 261 292 . . . . Encoder, Differential E8p 500cpr 1/4” Bore . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 261 293 . . . . Cbl Assy, Shielded 4 Wire 18” Axcess Encoder w/Plug . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 167 387 . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . 168 825 . . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 133 308 . . Ring, Retaining Ext .375 Shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 134 834 . . Hose, SAE .187 ID x .410 OD (Order By ft) . . . . . . . . . . . . . . . . . . . . . . . . 2ft
. . . . . . . . . . . . . . . . . . . . . 184 685 . . Adapter Assy, Gun/Feeder LH (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 149 959 . . . . Fitting, Brs Barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 179 265 . . . . Adapter, Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 604 538 . . . . Washer, Flat Stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 151 437 . . . . Knob, Plstc T 1.125 Lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 185 624 . . . . Screw, 010-32 x O.50 Hexwhd .40d Stl Pld Slffmg Trilob . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . . . 601 872 . . . . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 602 213 . . . . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 602 243 . . . . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 601 966 . . . . Screw, Cap Stl Hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 108 940 . . Screw, Cap Stl Hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 35 . . . . . . . . . . . . . . . 179 263 . . Cover, Drive Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 937 . . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
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-222 394 Page 45
OM-222 394 Page 46
Inlet Guide
221030
221030
221030
229919
229919
Wire Sizes
.023 to .040 in. (0.6 to 1.0mm)
.045 to .052 in. (1.1 to 1.4mm)
1/16 to 5/64 in. (1.6 to 2mm)
3/32 to 7/64 in. (2.4 to 2.8mm)
1/8 in. (3.2mm)
Wire Guides
*Accommodates .045 and .047 (3/64 in) wire
**Requires a low speed wire feeder
149522
149521
149520
149519
149518
Intermediate Guide
151042
151043**
151076**
151075
151074
151073
151072
151071
151070
”U” COGGED FOR
EXTREMELY SOFT
WIRE OR SOFT
SHELLED CORED
WIRES
1/16 in. (1.6mm)
.047 in. (1.2mm)
.035 in. (0.9mm)
Wire Size
221912
221912
221912
Inlet Guide
Nylon Wire Guides for Feeding Aluminum Wire
151060**
151059
151058
1/8 in. (3.2 mm)
151055
7/64 in. (2.8 mm)
151039
151054
151053
151041
151029
1/16 in. (1.6 mm)
151038
151037*
3/32 in. (2.4 mm)
151028
.052 in. (1.3/1.4 mm)
151057
151027
.045 in. (1.1/1.2 mm)
151056
161190
.040 in. (1.0 mm)
151052
151040
151026
.035 in. (0.9 mm)
”V” KNURLED FOR
HARDSHELLED
CORED WIRES
5/64 in. (2.0 mm)
151025
.030 in. (0.8 mm)
”U” GROOVE FOR
SOFTSHELLED
CORED WIRES
.068/.072 in. (1.8 mm)
151024
.023/.025 in. (0.6 mm)
WIRE SIZE
”V” GROOVE FOR
HARD WIRE
205937
205936
242417
Intermediate Guide
243235
243234*
243233
”U” GROOVE FOR
ALUMINUM WIRES
CONTAINS NYLON
WIRE GUIDES
Table 10-1. Drive Roll And Wire Guide Kits
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Guns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed.
* Replacement Parts (No labor)
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed one year after
the equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Filtair 400 and Industrial Collector
Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* Load Banks
* Motor Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2013-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
 2013 Miller Electric Mfg. Co.
2013−01
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