Miller AXCESS WIRE FEEDER User manual

Miller AXCESS WIRE FEEDER User manual
OM-211 076E
June 2005
Processes
MIG (GMAW) Welding
Description
Wire Feeder
Axcess
File: Advanced Manufacturing Systems
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual 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 4/05
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. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. 9-Pin Network Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Feeder Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Dual Schedule Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Feeder Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Process Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D
D
D
D
D
D
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D
D
D
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
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.
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.
OM-211 076 Page 1
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 when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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 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 can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-211 076 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
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
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-211 076 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-211 076 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1.
Symboles utilisés
Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints.
Y Indique un message de sécurité particulier
. Signifie NOTE ; n’est pas relatif à la sécurité.
2-2.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Dangers relatifs au soudage à l’arc
Y 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.
Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Y Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
D
D
D
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
D
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
D
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans
D
D
D
D
D
D
D
D
D
trous.
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.
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.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
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’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, dans l’ordre indiqué : 1) un poste à souder DC
à tension constante (à fil), 2) un poste à souder DC manuel (électrode)
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des
situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer le poste correctement et le mettre à la terre convenablement
selon les consignes du manuel de l’opérateur et les normes nationales,
provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer
que le fil de terre du cordon d’alimentation est bien raccordé à la borne
de terre du sectionneur ou que la fiche du cordon est raccordée à une
prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
D
D
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 métal-métal
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.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
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 FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour la santé.
D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces vapeurs.
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 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.
OM-211 076 Page 5
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures 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 pendant le soudage (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.
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 peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe 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 homologuées.
D Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
D Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
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 exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Avant de souder, retirer toute substance combustible de ses poches
telles qu’un allumeur au butane ou des allumettes.
D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un extincteur à proximité.
DES
PARTICULES
VOLANTES
peuvent blesser 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.
OM-211 076 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains
nues.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, rester
à distance.
D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc,
de gougeage ou de soudage par points.
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.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de soudage,
les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
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.
DES ORGANES MOBILES peuvent
provoquer des blessures.
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.
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 Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
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.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
D Lire le manuel d’utilisation avant d’utiliser ou
d’intervenir sur l’appareil.
D Utiliser uniquement des pièces de rechange
Miller/Hobart.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
SUR-
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.
D
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
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 PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
D
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de soudage.
2-4.
D Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
distance correcte et utiliser une terre et un blindage pour réduire
les interférences éventuelles.
D
D L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
D 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.
Proposition californienne 65 Avertissements
Y 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)
Pour les moteurs à essence :
Y Les gaz d’échappement des moteurs contiennent des produits
chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres problèmes de procréation.
Y Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Pour les moteurs diesel :
Y Les gaz d’échappement des moteurs diesel et certains de leurs
composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.
OM-211 076 Page 7
2-5.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale
2-6.
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-211 076 Page 8
1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − INTRODUCTION
3-1. 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)
46 lb
(20.9 kg)
Max Spool
Weight: 60 lb (27
kg)
Width: 12-1/2 in
(318 mm)
Height: 14-1/2 in
(368 mm)
SECTION 4 − INSTALLATION
4-1. Selecting A Location
Movement
Tipping
Y Do not move or operate
unit where it could tip.
2
OR
1
Location
Y Special installation may be required where gasoline or volatile
liquids are present − see NEC Article 511 or CEC Section 20.
Y Do not stack units. Beware of
tipping.
1
Lifting Forks
Use lifting forks to move unit.
4
Extend forks beyond opposite side
of unit.
2
Hand Cart
Use cart or similar device to move
unit.
3
3
18 in
(460 mm)
Rating Label
Use rating label to determine input
power needs.
4
Line Disconnect Device
Locate unit near correct input
power supply.
18 in
(460 mm)
loc_2 3/96 - Ref. 803 502-A
OM-211 076 Page 9
4-2. Connection Diagram
1
2
3
4
5
6
7
8
3
4
Welding Power Source
Wire Feeder
Gas Cylinder
Gas Hose
Network Feeder Cable
Negative (−) Weld Cable
Workpiece
Voltage Sensing Lead
(Optional)
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
5
2
1
9
Positive (+) Weld Cable
7
8
9
6
Ref. 801 915 / Ref. 803 501-A
OM-211 076 Page 10
4-3. Rear Panel Connections And Rotating Drive Assembly
1
2
9-Pin Network Receptacle
Shielding Gas Valve Fitting
Requires fitting with 5/8-18 righthand threads. Connect customersupplied gas hose.
3
4
5
6
7
Weld Cable Terminal
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
Rating Label Location
To rotate the drive assembly, loosen drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
7
1
2
3
4
5
6
Tools Needed:
9/16, 5/8 in
3/16 in
802 825-A / 803 503-A
OM-211 076 Page 11
4-4. 9-Pin Network Receptacle Information
9
F
E
G
H
I
D
C
A
B
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
I
Motor voltage +40 volts
4-5. Gun Recommendation Table
Process
Gun
GMAW − Hard or Cored Wires
400, 500, And 600 Amp
Air-Cooled Guns
GMAW − Pulse
Water-Cooled Guns
OM-211 076 Page 12
4-6. 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. Press Jog
button to feed wire out gun.
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-211 076 Page 13
4-7. Feeder Display At Power Up
1
2
1
Program
Volts
Time
WFS
Amps
Upper Display
Lower Display
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Gas Type
Trigger Hold
2
Trigger Control
Process Set Up
Power Source
Adjust
Feeder Set Up
Upper Display
Lower Display
Axcs
300/450/675
Axcess
Voltage Range
10
44
4-8. Dual Schedule Switch Options
1
DSS-9M 1
2
2
A
3
B
4
1
DSS-9M Part# 041 793
2
TR
B
1
1
2
2
2
3
3
3
4
4
A
OM-211 076 Page 14
Adapter
Maint 1P (Maintained-Contact
1-Pole Switch)
DSS-8 Part# 079 693 And Adapter
Part# 157 364
1
2
DSS-8
Maint 2P (Maintained-Contact
2-Pole Switch)
1
SECTION 5 − OPERATION
5-1. 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.
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.
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).
OM-211 076 Page 15
General Terms:
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.
5-2. Power Switch
1
Power Switch
1
803 504-A
OM-211 076 Page 16
5-3. Front Panel Controls
See
Section
5-5
See
Section
5-4
Program
Volts
Time
WFS
Amps
See
Section
5-6
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Trigger Control
Gas Type
Trigger Hold
Process Set Up
See
Section
5-9
Adjust
See
Section
5-8
Feeder Set Up
See
Section
5-7
OM-211 076 Page 17
5-4. 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
2
Pressing and holding the push
button will display current wire size,
wire type and process.
To reset feeder to factory settings,
turn power source off for 10
seconds. Press and hold button in
on power up, wait until top display
shows RST and bottom display
shows NO before releasing button.
Feeder Set Up button LED will
begin flashing. Turn Adjust knob to
change bottom display to show
YES, then press Feeder Set Up
button to confirm selection. The top
display will show CYCL and the
lower display will show PWR. Turn
welding power source power off for
10 seconds, then turn power back
on again.
5-5. Upper Display
3
1
2
4
Volts
Arc Adjust
5
1
Upper Display
The upper display shows voltage or arc
length. The unit displays both preset voltage
or arc length and actual voltage. When
welding, actual arc voltage is displayed.
2
Upper Display Push Button
Press the button to illuminate the LED and
allow changing information in the display.
Release button to display voltage.
3
Upper Display Push Button LED
The upper display push button LED
OM-211 076 Page 18
illuminates to indicate that information
displayed can be changed by the Adjust
control.
4
Volts LED (Weld Voltage In MIG)
5
Arc Adjust LED (Pulse Mode)
The LEDs below the display illuminate to
indicate which value is being shown.
At any time while welding, the unit permits the
adjustment of the weld voltage and overrides
the display of actual arc voltage.
To activate Carbon Arc Cutting (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
Cutting process selection.
5-6. Lower Display
7
3
Time
1
2
4
WFS
Amps
Arc Ctl
5
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.
6
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.
During a welding program operation, it is
possible to change WFS (wire feed speed) by
using the Adjust knob regardless of the active
program sequence that appears on the display.
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
additional functions when entering the
sequence and trigger control functions
(see Section 5-7).
OM-211 076 Page 19
5-7. Feeder Set Up Push Button
3
4
Sequence
5
Trigger Control
Start
Time
Trigger Hold
2
1
Weld
Time
Preflow
Time
Crater
Time
Postflow
Time
6
Welding Sequence Diagram
Feeder Set Up
1
2
Feeder Set Up Push Button
Feeder Set Up Push Button LED
Press button to choose sequence, trigger
control, or trigger hold.
3
4
5
6
Sequence LED
Trigger Control LED
Trigger Hold LED
Lock LED (Access Allowed Only By
Using An Optional PDA With File
Management Software)
• When the Feeder Set Up button is pressed
while in standby, the Feeder Set Up push
button LED illuminates and the top display
will be active. Use the Adjust control to
select preflow (PRE), start (STRT), crater
(CRTR), or postflow (POST) parameters.
• Press the lower display push button to allow
the bottom display to become active. The
time LED will automatically begin flashing
and the unit will be in the time mode. Initially,
all sequences will appear as off. Use the
Adjust control display time and enable the
time sequence. Setting a time automatically
enables a sequence. To turn off a sequence,
change time setting to OFF.
• If the sequence has a voltage or arc adjust
setting, pressing the lower display push
button a second time will cause either volts
or arc adjust to appear on the display. Use
the Adjust control to set either parameter.
the top display to become active. Use the
Adjust control to cycle through trigger
control methods as follows: dual schedule,
trigger hold, trigger dual schedule, program
select, 4T (see Section 5-1). The lower
display will show the current state of each
trigger control method as being either on or
off. Not all trigger control methods are
compatible with each other, and turning on
certain functions will cause other trigger
functions to turn off.
• Press the lower display push button a fourth
time will cycle the display back to time.
• Press the lower display push button to allow
the bottom display to become active. Use
the Adjust control to turn selected trigger
control methods on or off. If trigger hold is
set to on, the trigger hold LED will illuminate.
Note: if 4T is set to on, trigger hold will
automatically be set to on since this
parameter is necessary for the 4T function.
• Press the Feeder Set Up button a second
time to go to Trigger Control mode and allow
• Press the Feeder Set Up button a third time
to cycle back to standby mode.
• If the sequence has a wire feed setting,
pressing the lower display push button a
third time will cause wfs to appear on the
display. Use the Adjust control to set wire
speed parameter.
5-8. Adjust Control
1
1
Adjust
OM-211 076 Page 20
Adjust Control
The Adjust control is used to
change various sequence parameters, and to select various sequences. Refer to the section for
the function in question for information related to using the Adjust control.
5-9. Process Set Up Push Button
1
2
3
Process
3
Process Set Up Push Button
Process Set Up LED
Program Selection LEDs
Wire Type
Gas Type
2
1
Process Set Up
• Press the Process Set Up push button the
first time will illuminate the button LED and
Process LED above the button. Both
displays will show the current process and,
if desired, these displays will be active to
allow selecting a new process. Default
processes are MIG, PULSE, and ACCU
PULSE.
• Pressing the Process Set Up push button a
second time will illuminate the Wire Type
LED and the bottom display will show wire
types available for the selected process. To
make a selection, rotate the Adjust control.
• Pressing the Process Set Up push button a
third time will keep Wire Type LED lit, but the
upper display will be active and show wire
sizes available for the current wire type. To
make a selection, rotate the Adjust control.
• Pressing the Process Set Up push button a
fourth time will illuminate the Gas Type LED
and both displays will show available gas
selections for the process, and wire type
and wire size selection. To select an item,
rotate the Adjust control.
• Pressing the Process Set Up push button a
fifth time will load the program that matches
the selected parameters (process, wire
type, wire size, gas). The upper display will
show PROG and the lower display will show
LOAD.
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 software,
the upper display will show CUST and the
lower display will show PROG. The Adjust
control remains active to allow loading a
standard program in place of the custom
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 5-1. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2,
98% Argon/2% O2
CO2
C10
C15
C25
C5
OX5
OX2
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2
(81Ar/18HE/1CO2
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO 2
MIG/RMD/Accu-pulse)
OX2
Tri Gas
71, 76, 86R, 409,
439
90% Argon/10% CO2
C10
98% Argon/2% O2
OX2
4XXX, 5XXX
100% Argon
ARGN
Cored Tubular Wire
Aluminum
MCOR
ALUM
Tri Gas
* Not all wire types may be available with your unit.
OM-211 076 Page 21
5-10. Jog/Purge
1
2
3
Jog/Purge Push Button
Adjust Control
Gun Trigger Receptacle
2
3
1
803 505-A
Pressing the Jog/Purge switch allows the
operator to jog wire without energizing the
weld power or gas valve circuit.
displays the “ERR STRT“ message to
inform the operator that the trigger is
activated.
• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog
operation for a maximum of 30 seconds. If
the gun trigger is still activated after 30
seconds, the jog operation is terminated to
prevent complete unspooling of the wire, in
the case of a damaged gun. The unit
• Jog speed can be adjusted by the Adjust
control when the unit is jogging wire. The
unit displays jog speed when the unit is
being jogged.
OM-211 076 Page 22
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before
welding and to preset gas pressure at the
regulator.
• 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 software. Pressing the
Jog/Purge switch or gun trigger during Auto
Threading will terminate the automatic feed
operation.
5-11. Reset Mode
Program
. Reset mode is not active when
Program Lock is enabled.
RST
Volts
Time
NO
WFS
Amps
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
Arc Adjust
Arc Ctl
. System configuration data will be
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Process Set up
Adjust
lost during the Reset operation.
Feeder Set Up
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).
Program
RST
Volts
Time
YES
WFS
Amps
Volts
WFS
Trigger Hold
Adjust
RST
Time
YES
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Program
Arc Adjust
Feeder Set Up
Rotate Adjust knob to change NO
to YES.
Amps
Volts
WFS
Trigger Hold
Adjust
CYCL
Time
Arc Adjust
PWR
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Program
Arc Adjust
Feeder Set Up
Amps
Process Set up
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Adjust
Feeder Set Up
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 / 803 504-A
OM-211 076 Page 23
SECTION 6 − SETTING SEQUENCE PARAMETERS
6-1. Sequence Parameters In A Program
. For more information on
Sequence mode, see Feeder
Set Up Push Button in Section
5-7.
Sequence
If time is set to Off in Weld
sequence, welding continues until
gun trigger is released.
Parameters
Seconds
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
1. Preflow
Off-5.0
. Maximum
2. Postflow
Off-5.0
Volts/Trim
IPM
3. Start
10.0-44.0/
0-99
40-1400/
0-99
Off-5.0
4. Crater
10.0-44.0/
0-99
40-1400/
0-99
Off-5.0
IPM may actually
be lower depending on wire
size and gas combination.
X = Setting available.
Weld
Crater
Time
Preflow
Time
Start
Time
Postflow
Time
Time
Preflow
Trigger
Pressed
OM-211 076 Page 24
Start
Weld
Crater
Trigger
Released
Postflow Sequence
End
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Clean and
tighten
weld
terminals.
Replace
unreadable
labels.
Replace
cracked
parts.
Check
14-pin cord.
Repair or
replace
cracked
weld
cable.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
monthly.
Or
Clean
drive rolls.
OM-211 076 Page 25
7-2. Diagnostics
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
ERR
ERR
ERR
SENS
TACH
MOTR
WFS
STRT
STOP
Indicates an arc
start error.
Indicates an arc
stop error.
Indicates a voltage
sense error.
Indicates a
tachometer error.
Indicates a motor
error.
Indicates a wire
feed speed error.
ERR
ERR
ERR
ERR
ERR
ERR
FLOW
COOL
FTP
GND
STUK
PSF
Indicates a gas
flow error.
Indicates a coolant
flow error.
ERR SENS
• The voltage sense error indicates no
voltage sensing feedback signal. Check
connections at feeder and welding power
source. Press Jog/Purge button to clear
error.
ERR TACH
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The motor
speed is regulated through the monitoring of
voltage and current. Press Jog/Purge
button to clear error.
ERR MOTR
• The motor error indicates that the motor
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle. Press Jog/Purge button to clear error.
ERR WFS
• The wire feed speed error indicates actual
wire feed speed does not match wire feed
speed command. Press Jog/Purge button
to clear error.
OM-211 076 Page 26
Indicates a file
transfer point error.
Indicates a ground
current error.
ERR STRT
• The start error occurs if the user has the
trigger held for more than two minutes
without striking an arc, or if the user holds
the trigger past the postflow phase in a
timed weld. This error also occurs if the
trigger is held when the feeder is powered
up. The error may be cleared by releasing
the trigger, and pressing the Jog/Purge
button.
ERR STOP
• The stop error occurs as result of
obstructions in the wire feed system or a
faulty wire drive system. Check wire feed
and wire drive systems. Press Jog/Purge
button to clear error.
ERR FLOW
• The flow error indicates no gas flow to the
gun. The error may be reset by
reestablishing gas flow to the gun, and then
pressing the Jog/Purge button.
ERR COOL
• The cool error indicates no coolant flow in
water flow switch option. The error may be
reset by reestablishing coolant flow to the
gun, and then pressing the Jog/Purge
button.
Indicates a wire
stuck error.
Indicates a primary
power error.
ERR FTP
• The file transfer error occurs if data does
not transfer to the feeder correctly. Press
Jog/Purge button to clear error, and transfer
data to feeder again.
ERR GND
• The ground current error occurs if weld
current is detected in the earth ground
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Press
Jog/Purge button to clear error.
ERR STUK
• The stuck error occurs if the welding wire
sticks to the workpiece at the end of a weld.
May be caused by poor weld conditions.
The error may be cleared by cutting wire
from workpiece, and pressing the Jog/
Purge button.
ERR PSF
• The primary power error occurs if the
primary power circuit inside the feeder is not
functioning correctly. Check feeder
connections. Press Jog/Purge button to
clear error.
7-2.
Diagnostics (Continued)
ERR
ERR
ERR
ERR
UNIT
UIM
TEMP
LINE
ARC
POL
MEM
MEM
Indicates a
temperature error.
Indicates a line
error.
Indicates an arc
error.
Indicates a polarity
error.
Indicates a memory
CRC PCM error.
Indicates a memory
CRC UIM error.
MOTR
WELD
MOTR
PLS
OVER
LOW
MEM
WAIT
COM
WAIT
CRNT
WFS
Indicates a UIM
communication error.
Indicates an
overcurrent error.
Indicates a memory
CRC motor error.
Indicates a weld
cycle wait error.
ERR TEMP
• The temperature error indicates welding
power source has overheated and
shutdown. The error may be cleared by
allowing unit to cool down, and pressing the
Jog/Purge button.
ERR LINE
• The line error indicates input power is
outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.
ERR ARC
• The arc error indicates an arc outage
occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.
Indicates a motor
communication error.
ERR POL
• The polarity error indicates the polarity is
different than the selected polarity. Check
and correct weld cable connections. Press
Jog/Purge button to clear error.
UNIT MEM
• The unit memory error indicates the PCM
board lost memory data. Press Jog/Purge
button to clear error.
UIM MEM
• The uim memory error indicates user
interface board lost memory data. Press
Jog/Purge button to clear error.
MOTR MEM
• The motor memory error indicates motor
board lost memory data. Press Jog/Purge
button to clear error.
WELD WAIT
• The weld wait error indicates unit was not
ready for a weld sequence. Press Jog/
Purge button to clear error.
Indicates a low WFS
command error.
MOTR COM
• The motor communication error indicates motor board lost data communications. Press Jog/Purge button to clear error.
PLS WAIT
• The uim communication error indicates
user
interface
board
lost
data
communications. Press Jog/Purge button
to clear error.
OVER CRNT
• The over current error indicates welding
power source primary current is too high.
Check and correct input power. Press Jog/
Purge button to clear error.
LOW WFS
• The low wire feed speed error indicates
actual wire feed speed is lower than wire
feed speed command. Check for
obstructions in the wire feed system or a
faulty wire drive system. Press Jog/Purge
button to clear error.
OM-211 076 Page 27
7-2.
Diagnostics (Continued)
RMD
OVER
UNIT
REL
TRIG
ERR
DONE
AVER
COMM
TRIG
STUK
UNKN
Indicates RMD
demo is done.
Indicates an over
average current error.
Indicates a CRC
PCM bus error.
Indicates a contactor
on error.
Indicates a trigger
closed error.
Indicates an
unknown error.
RMD DONE
UNIT COMM
TRIG STUK
• The RMD done message indicates the
RMD demo is completed. Pressing
Jog/Purge button will change the screen to
CYCL PWR on the display. Turn unit power
off and back on again.
• The unit communication error indicates
the data bus on the PCM board is not
functioning properly. Press Jog/Purge
button to clear error.
• The trigger stuck error indicates the user
held the gun trigger during power up. Press
Jog/Purge button to clear error.
OVER AVER
REL TRIG
• The over average error indicates that
current is outside the average range for the
set program parameters. Check and correct
program parameters. Press Jog/Purge
button to clear error.
• The release trigger error indicates the
user held the gun trigger after a timed weld
was completed causing the contactor to
remain on. Press Jog/Purge button to clear
error.
OM-211 076 Page 28
ERR UNKN
• The unknown error indicates a
malfunction in the system somewhere.
Press Jog/Purge button to clear error.
7-3. Troubleshooting
Y 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 4-2).
Electrode wire feeding stops or feeds
erratically during welding.
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 4-6).
Change to correct size drive roll (see Table 9-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
OM-211 076 Page 29
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram
OM-211 076 Page 30
211 005-D
OM-211 076 Page 31
SECTION 9 − PARTS LIST
. Hardware is common and
not available unless listed.
6
7
8
5
9
10
11
12
11
10
13
15
16
17
4 − Fig 9-3
3
14
22
2
18
1
19
20
21 − Fig 9-2
803 506-C
Figure 9-1. Main Assembly
OM-211 076 Page 32
Item
No.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
. . . . . . . . . . . . . . . 159 647
. . . . . . . . . . . . . . . 159 646
. . . . . . . . . . . . . . . 159 360
. . . . . . . . . . . . . . . . Fig 9-3
. . . . . . . . . . . . . . . 141 753
. . . . . . . . . . . . . . . 058 427
. . . . . . . . . . . . . . . 180 571
. . . . . . . . . . . . . . . 010 233
. . . . . . . . . . . . . . . 057 971
. . . . . . . . . . . . . . . 010 191
. . . . . . . . . . . . . . . 058 628
. . . . . . . . . . . . . . . 058 428
. . . . . . . . . . . . . . . 135 205
. . . . . . . . . . . . . . . 200 556
. . . . . . . . . . . . . . . 201 781
. . . . . . . . . . . . . . . 156 243
. . . . . . . . . . . . . . . 145 639
. . . . . . . . . . . . . . . 200 552
. . . . . . . . . . . . . . . 134 306
. . . . . . . . . . . . . . . 200 557
. . . . . . . . . . . . . . . . Fig 9-2
. . . . . . . . . . . . . . . 216 695
. . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DRIVE ASSEMBLY, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HUB & SPINDLE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SHAFT, support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPRING, cprsn .970 OD x .120 wire x 1.250pld . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl keyed 1.500dia x .125thk . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, stl slflkg hex reg .625-11 w/nylon insert . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, w/extension 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 . . . . . . . . . . . . . . . . . .
. . STIFFENER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, w/terminals (.027UF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
4
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-211 076 Page 33
. Hardware is common and
not available unless listed.
1
9
7
2
10
6
5
11
4
25
3
12
17
16
15
8
14
16
24
20
13
19
21
23
22
803 507-C
Figure 9-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Control Box (Fig 9-1 Item 21)
. . . 1 . . . . . . . . . . . . . . . 134 464
. . . 2 . . . . . . . . . . . . . . +212 781
. . . . . . . . . . . . . . . . . . . . *211 164
. . . 3 . . . . . . . . . . . . . . . 210 655
. . . 4 . . . . . . . . . . . . . . . 213 887
. . . 5 . . . . PC7 . . . . . 204 049
. . . 6 . . . . . . . . . . . . . . . 212 808
. . . 7 . . . . PC6 . . . . *209 681
. . . 8 . . . . . . . . . . . . . . . 211 003
. . . 9 . . . . . . . . . . . . . . . 010 494
. . . 10 . . . . . . . . . . . . . . . 057 357
. . . 11 . . . . RC1 . . . . . 211 018
. . . . . . PLG43,46,49,
72 . . . . . . 115 093
. . . 12 . . . . . . . . . . . . . . . 605 227
. . . 13 . . . . . . . . . . . . . . . 219 047
. . . 14 . . . . . . . . . . . . . . . 134 201
. . . 15 . . . . . . . . . . . . . . . 097 132
. . . 16 . . . . . . . . . . . . . . . 211 002
. . . 17 . . . . PC2 . . . . . 212 493
. . . 18 . . . . . S1 . . . . . . 213 632
. . . 19 . . . . PC1 . . . . . 212 459
. . . 20 . . . . RC4 . . . . . 048 282
. . . 21 . . . . . . . . . . . . . . . 211 085
OM-211 076 Page 34
. . LABEL, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER, feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, pc card switch/overlay (including) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NAMEPLATE, overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT CARD ASSY, display/micro w/program . . . . . . . . . . . . . . . . .
. . BAFFLE, pc mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENCLOSURE, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap−in nyl 1.375 id x 1.750 mtg hole . . . . . . . . . . . . . . . . . .
. . BUSHING, snap−in nyl .937 id x 1.125 mtg hole . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, circ 97/met 9 pin size 20 rcpt . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
. . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 750−14 knurled1.68dia .41h nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, 40 VDC 2 way custom port 1/8 orf w/frict . . . . . . . . . . . . . . . . . . .
. . STAND−OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND−OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENCLOSURE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, motor filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, rocker dpdt 10A 250VAC/20A 30VAC on-none-on . . . . . . . . .
. . CIRCUIT CARD ASSY, trigger filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
4
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Control Box (Fig 9-1 Item 21) (Continued)
. . . 22 . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . .
. . . 23 . . . . . S2 . . . . . .
.....................
.....................
. . . 24 . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . .
.....................
.....................
.....................
.....................
.....................
. . . . . . . . . PLG47 . . . .
. . . . . . . . . PLG48 . . . .
. . . . . . . . . . PLG4 . . . . .
. . . . . . . . . PLG81 . . . .
. . . . . . . . . PLG10 . . . .
. . . . . . . . . PLG50 . . . .
. . . . . . . . . PLG44 . . . .
. . . . . . . . . PLG45 . . . .
. . . . . . . . . PLG42 . . . .
. . . . . . . . . PLG40 . . . .
.....................
211 073
210 998
200 295
131 056
131 052
179 851
216 866
216 696
038 855
224 383
216 872
213 004
115 094
202 592
136 810
115 092
130 203
136 810
131 058
188 352
131 054
201 665
207 676
. . NAMEPLATE, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH ASSY, jog/purge (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, rocker spdt 15A 12V (on)-off-(on) . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer 1.670 dia x .250 id push on w/spring . . . . . . . . . . . . . . . .
. . FILTER ASSY, sense lead (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, w/terminals (.027UF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 20 amp 2 pole screw term . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RESISTOR, w/terminals (2 K 5 watt) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CABLE, volt sense 7 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CABLE, volt sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING RCPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING RCPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING RCPTPLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . .
. . STAND−OFF, no 6-32 x .250 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-211 076 Page 35
. Hardware is common and
11
not available unless listed.
18
12
13
14
See Table 9-1 For
Drive Roll & Wire Guide Kits
15
16
17
9
1
2
3
4
5
7
6
8
18
19
10
15
20
33
30
21
22
23
24
32
31
25
35
26
29
27
28
34
3
4
6
5
2
1
802 950-B
Figure 9-3. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-3. Drive Assembly, Wire (Fig 9-1 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 . . . . . . . . . . . . . . . 203 641
. . . 13 . . . . . . . . . . . . . . . 182 156
. . . 14 . . . . . . . . . . . . . . . 182 155
. . . 15 . . . . . . . . . . . . . . . 132 746
. . . 16 . . . . . . . . . . . . . . . 203 633
. . . 17 . . . . . . . . . . . . . . . 203 632
. . . 18 . . . . . . . . . . . . . . . 133 739
. . . 19 . . . . . . . . . . . . . . . 203 637
. . . 20 . . . . . . . . . . . . . . {199 447
. . . . . . . . . . . . . . . . . . . . . 604 311
. . . . . . . . . . . . . . . . . . . . . 603 115
. . . 21 . . . . . . . . . . . . . . . 167 387
. . . 22 . . . . . . . . . . . . . . . 168 825
. . . 23 . . . . . . . . . . . . . . . 133 308
. . . 24 . . . . . . . . . . . . . . . 134 834
OM-211 076 Page 36
. . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . SPACER, carrier drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . PIN, rotation arm rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . ARM, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . SPACER, flat stl .257 ID x .619 OD x .105 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . RING, retaining ext .250 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . MOTOR, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PRESSURE ARM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . KNOB, w/extension short pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . WASHER, flat buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . 2
. . . . KNOB, w/extension long pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ENCODER, quadrature 500PPR incremental 5V shaftless . . . . . . . . . . . . 1
. . . . GROMMET, rbr .250 ID x .375mtg hole .062 groove . . . . . . . . . . . . . . . 1
. . WEATHER STRIPPING, adh .125 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . DRIVE, pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 2ft
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-3. Drive Assembly, Wire (Fig 9-1 Item 4) (continued)
.....................
. . . 25 . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . .
.....................
184 685
149 959
179 265
604 538
151 437
185 624
601 872
602 213
602 243
601 966
108 940
179 263
178 937
. . ADAPTER ASSY, gun/feeder LH (including) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, brs barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ADAPTER, gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KNOB, plstc T 1.125 lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, 010-32 x o.50 hexwhd .40D stl pld slffmg trilob . . . . . . . . . . . .
. . . . NUT, stl hex full fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, cap stl hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, drive roll (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
1
4
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.
Table 9-1. Drive Roll And Wire Guide Kits
Wire Size
V-GROOVE
InterInter
mediate
Guide
4 Roll
Kit
Drive
Roll
U-GROOVE
VK-GROOVE
UC-GROOVE
Fraction
Metric
Inlet
Guide
.023-.025 in.
0.6 mm
150 993
149 518
151 024
087 130
.030 in.
0.8 mm
150 993
149 518
151 025
053 695
.035 in.
0.9 mm
150 993
149 518
151 026
053 700
.040 in.
1.0 mm
150 993
149 518
161 189
053 696
.045 in.
1.1/1.2 mm
150 994
149 519
151 027
053 697
151 037
053 701
151 053
132 957
151 070
083 489
.052 in.
1.3/1.4 mm
150 994
149 519
151 028
053 698
151 038
053 702
151 054
132 956
151 071
083 490
1/16 in.
(.062 in.)
1.6 mm
150 995
149 520
151 029
053 699
151 039
053 706
151 055
132 955
151 072
053 708
.068-.072 in.
1.8 mm
150 995
149 520
151 056
132 959
5/64 in.
(.079 in.)
2.0 mm
150 995
149 520
151 040
053 704
151 057
132 960
151 073
053 710
3/32 in.
(.094 in.)
2.4 mm
150 996
149 521
151 041
053 703
151 058
132 961
151 074
053 709
7/64 in.
(.110 in.)
2.8 mm
150 996
149 521
151 042
053 705
151 059
132 962
151 075
053 711
1/8 in.
(.125 in.)
3.2 mm
159 997
149 522
151 043
053 707
151 060
132 963
151 076
053 712
4 Roll
Kit
Drive
Roll
4 Roll
Kit
Drive
Roll
151 036
072 000
151 052
132 958
4 Roll
Kit
Drive
Roll
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls.
OM-211 076 Page 37
Notes
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
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.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
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 1/05
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)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2005 Miller Electric Mfg. Co.
1/05
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