Miller CONTINUUM SINGLE WIRE FEEDER CE User manual

Miller CONTINUUM SINGLE WIRE FEEDER CE User manual
OM-276631B
2017−10
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Wire Feeder
Continuum
Single Feeder
®
CE And Non−CE Models
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Advanced Manufacturing Systems
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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 2017−06
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Wire Type, Size, And Wire Feed Speed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Power Source And Wire Feeder Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Feeder Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Mounting Hole Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Connecting Weld Output Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Remote 10 Wire Feeder Control Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Control Cable Connections (CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Control Cable Connections (Non CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Wire Feeder Lower Front Panel Connections (CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Wire Feeder Lower Front Panel Connections (Non CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Shielding Gas Hose And Cooler Connections (CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Shielding Gas Hose Connection (Non CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Jog/Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Installing Wire Guides And Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18. Wire Feeder User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19. Description Of Front Panel Controls (See Section 5-18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-20. Wire Feeder Lower Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-21. LCD Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-22. Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-23. Logs Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-24. Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-25. Creating, Changing And Saving a Weld Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-26. Trigger Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
8
9
9
11
12
12
12
12
13
14
14
15
15
16
17
18
19
19
20
20
21
21
22
23
24
25
26
28
29
30
31
31
32
32
33
33
TABLE OF CONTENTS (continued)
5-27. Weld Sequence Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-28. Feedback Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-29. System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-30. Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-31. USB Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Error Code Troubleshooting Description And Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
34
35
35
36
36
37
37
38
41
42
44
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
301195010
Product
Continuum Single Feeder CE
Council Directives:
·2014/35/EU Low voltage
·2014/30/EU Electromagnetic compatibility
·2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-2:2013 Arc welding equipment – Part 2: Liquid cooling systems
• IEC 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
January 25, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
275625A
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-276631 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-276631 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-276631 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-276631 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
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 !
D 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).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
OM-276631 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
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 pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-276631 Page 6
chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
OM-276631 Page 7
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-276631 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Disconnect input plug or power before working on machine.
Safe5 2017−04
Keep your head out of the fumes.
Safe6 2017−04
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
OM-276631 Page 9
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2017−04
Do not remove or paint over (cover) the label.
Safe20 2017−04
Disconnect input plug or power before working on machine.
Safe30 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2017−04
Environmental Protection Use Period (China)
Safe123 2016−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-276631 Page 10
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
Output
X
Amperes
V
Direct Current
(DC)
Volts
IP
Degree Of
Protection
Duty Cycle
Wire Feed
Percent
Input
Cold Jog (Inch)
Towards
Workpiece
Purge By Gas
Fast
Constant Current
Circuit Breaker
Constant Voltage
Slow
Trigger Hold Off
Trigger Hold On
Rated Welding
Current
Increase
Conventional Load
Voltage
Locked
Process
Read Instructions
I1
A
U1
Primary Voltage
I2
U2
Primary Current
Sequence
Program
Wire Type
Gas Type
Variable
Inductance
Arc Length
Line Connection
USB
Three Phase
Output On
Arc Control
Synergic Mode
Active
Push Button
Time
Memory
Rotating Knob And
Push Button
Material Thickness
Notes
OM-276631 Page 11
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Specifications
Input Power
Welding Power
Source Type
Wire Feed Speed
Range*
50 VDC
Continuum Series
Standard:
50−1000 ipm
(1.27−25.4mpm)
Welding Circuit
Rating
Wire Diameter Range
.035 To .5/64 in.
(0.9 To 2 mm)
72 Volts
500 Amperes,
100% Duty
Cycle
Max Spool Capacity:
18 in. (457 mm)
Max Spool Weight:
60 lb (27 kg)
Overall
Dimensions
Without
Spool Covers
Overall
Dimensions
With
Spool Covers
Weight
Height:
13.94 in.
(354 mm)
Width:
16.69 in.
(424 mm)
Length:
27.59 in.
(701 mm)
Height:
16.52 in.
(419 mm)
Width:
17.39 in.
(442 mm)
Length:
29.55 in.
(750 mm)
42.85 lb
(19.4 kg)
*See Section 4-3 for detailed information on wire type, wire size, and wire feed speed.
4-3. Wire Type, Size, And Wire Feed Speed Table
Wire Size
Solid Steel
.035 in.
.045 in.
.052 in.
.062 in.
5/64 in.
(0.9 mm)
(1.1/1.2 mm)
(1.3/1.4 mm)
(1.6 mm)
(2.0 mm)
MIG:
MIG:
MIG:
MIG:
50 To 1000 ipm
50 To 1000 ipm
50 To 800 ipm
50 To 600 ipm
(1.27 To 25.40 mpm)
(1.27 To 25.40 mpm)
(1.27 To 20.32 mpm)
(1.27 To 15.24 mpm)
Accupulse:
Accupulse:
Accupulse:
Accupulse:
75 To 1000 ipm
50 To 1000 ipm
50 To 800 ipm
50 To 600 ipm
(1.27 To 25.40 mpm)
(1.27 To 20.32 mpm)
(1.27 To 15.24 mpm)
(1.91 To 25.40 mpm)
Metalcore Steel
Flux cored Steel
Notes
OM-276631 Page 12
N/A
N/A
MIG:
MIG:
MIG:
50 To 1000 ipm
50 To 900 ipm
50 To 700 ipm
(1.27 To 25.40 mpm)
(1.27 To 22.86 mpm)
(1.27 To 17.78 mpm)
Accupulse:
Accupulse:
Accupulse:
50 To 800 ipm
50 To 700 ipm
50 To 600 ipm
(1.27 To 20.32 mpm)
(1.27 To 17.78 mpm )
(1.27 To 15.24 mpm)
MIG:
MIG:
MIG:
N/A
N/A
MIG:
200 To 900 ipm
200 To 900 ipm
150 To 800 ipm
100 To 400 ipm
(5.08 To 22.86 mpm)
(5.08 To 22.86 mpm)
(3.81 To 20.32 mpm)
(2.54 To 10.16 mpm)
4-4. Environmental Specifications
A. IP Rating
IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21S 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
ce-emc 3 2014-07
C. Temperature Specifications
Operating Temperature Range
Storage Temperature Range
14 to 104 °F (−10 to 40°C)
−4 to 131 °F (−20 to 55°C)
Temp_2016- 07
D. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
OM-276631 Page 13
SECTION 5 − INSTALLATION
5-1. Power Source And Wire Feeder Site Selection
Movement
!
Do not put feeder where
welding wire hits cylinder.
!
Do not move or operate
unit where it could tip.
OR
1
2
Location And Airflow
3
!
Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
!
Do not move or operate equipment
where it could tip.
1
Hand Cart
Use cart or similar device to move unit.
2
Lifting Forks
Use lifting eye or lifting forks to move unit.
If using lifting forks, extend forks beyond
opposite side of unit.
3
18 in.
(460 mm)
Line Disconnect Device
Locate unit near correct input power supply.
18 in.
(460 mm)
Loc_contfeeder 2015-07
OM-276631 Page 14
5-2. Feeder Location
1
Lifting Eye
When a feeder is installed on top of
power source, lift eye is inserted
through slot in feeder base.
1
Loc_contfeeder 2015-07
5-3. Mounting Hole Location
. Holes are designed for 3/8 in.
hex head bolts.
2.8 in. 2.8 in. 2.8 in. 2.8 in.
(71 mm) (71 mm) (71 mm) (71 mm)
3.975 in.
(101 mm)
7.95 in.
(202 mm)
Ref. 266 419-B
OM-276631 Page 15
5-4. Connecting Weld Output Cable
!
Turn off power before connecting to
weld output tabs or receptacles.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Tools Needed:
3/4 in. (19 mm)
Ensure all connections are tight.
Tab Connection
. Do not place anything between weld
cable terminal and output tab. Make
sure that the surfaces of the weld cable
terminal and output tab are clean.
1
2
3
Wire Feeder Side View
with Door Open
4
5
6
7
8
1
Positive Connection Terminal
Correct Weld Cable Connection For
Single Cable
Correct Weld Cable Connection For
2/0 And Larger Double Cables
Incorrect Weld Cable Connection
Weld Output Terminal Bolt
Weld Cable Terminal
Supplied Washer
Supplied Nut
Remove supplied nut and bolt from weld
output terminal. Insert bolt through hole in
weld cable terminal and hole in weld output
terminal. Screw nut onto bolt until weld
cable terminal is tight against output terminal. Torque to 27−33 ft lb (36.6−45 N·m).
2
5
6
7
8
4
3
5
6
7
8
2/0 and larger double cables
Ref. 259144-C / Ref. 259120-B
OM-276631 Page 16
5-5. Remote 10 Wire Feeder Control Receptacle RC2 Information
Socket
C
I
G
J
D
A
+50 Volts DC Common
B
+50 Volts DC Common
C
Voltage Sense
D
+50 Volts DC Power
E
+50 Volts DC Power
F
ENET Rx −
G
ENET Tx −
H
Drain
I
ENET Tx +
J
ENET Rx +
H
A
B
Socket Information
F
E
Ref. 277156-B / Ref. 259119−D
Notes
OM-276631 Page 17
5-6. Connection Diagram
1
2
3
4
5
6
7
8
9
10
3
4
. Shielding gas pressure not to
2
exceed 100 psi (689 kPa).
5
6
9
10
1
8
7
Notes
OM-276631 Page 18
Welding Power Source
Wire Feeder
Gas Cylinder
Gas Hose
Feeder Cable
Electrode Cable
Work Cable
Volt Sense Lead
Welding Gun
Workpiece
5-7. Control Cable Connections (CE Model)
1
10-Socket Control Receptacle RC2
Connect control cable to receptacle on
rear of welding power source and wire
feeder.
1
1
Wire Feeder
Rear View
Welding Power Source
Rear View
Ref. 259119-D / Ref. 277156-B
5-8. Control Cable Connections (Non CE Model)
1
10-Socket Control Receptacle RC2
Connect control cable to receptacle on
rear of welding power source and wire
feeder.
1
1
Wire Feeder
Rear View
Welding Power Source
Rear View
Ref. 259119-D / Ref. 259144-C
OM-276631 Page 19
5-9. Wire Feeder Lower Front Panel Connections (CE Model)
1
4-Socket Gun Trigger
Receptacle
Connect gun trigger plug to
appropriate receptacle on feeder.
2
3
1
2
3
Water-In Quick Connect
Fitting
Water-Out Quick Connect
Fitting
Ref. 277156-B
5-10. Wire Feeder Lower Front Panel Connections (Non CE Model)
1
4-Socket Gun Trigger
Receptacle
Connect gun trigger plug to
appropriate receptacle on feeder.
1
Ref. 259144-C
OM-276631 Page 20
5-11. Shielding Gas Hose And Cooler Connections (CE Model)
1
2
3
Shielding Gas Fitting
Water−In Quick Connect
Fitting
Water−Out Quick Connect
Fitting
Connect hose from shielding gas
supply to fitting on rear of feeder.
1
2
3
Wire Feeder Rear View
Ref. 301195010-002
5-12. Shielding Gas Hose Connection (Non CE Model)
1
Shielding Gas Fitting
Connect hose from shielding gas
supply to fitting on rear of feeder.
1
Wire Feeder Rear View
Ref. 259 144-C
OM-276631 Page 21
5-13. Jog/Retract Switch
3
1
2
1
2
Jog/Retract Switch
Jog Symbol
Press Jog/Retract switch to the
right to Jog wire. Jog switch will
feed wire through MIG gun during
installation without energizing the
weld output.
3
Retract Symbol
Press Jog/Retract switch to the left
to retract wire. Retract switch will
feed wire backward.
. If using the retract button to respool wire, the wire spool will
need to be manually turned to
ensure proper respooling.
Wire Drive Assembly
Ref. 259144-C
Notes
OM-276631 Page 22
5-14. Rotating Drive Assembly
1
2
Retaining Knob And Pin
Adjustment Holes (8)
Each hole location is spaced at 5
degree increments. There are a total of eight holes for a range of 40
degrees. The second hole from the
bottom positions the wire drive assembly parallel with the feeder
base.
To rotate the drive assembly, pull
retaining knob out and hold it while
rotating drive assembly. Release
knob at desired position to lock
drive assembly in place.
3
Wire Angle at Drive Assembly
Rotate the drive assembly to reduce bends in the MIG gun cable.
2
Wire can be setup to feed off either
the top or bottom of wire spool. Select the option that results in the
straightest possible path into drive
assembly.
1
3
Good
3
Wire Feeds Off Top Of Spool
Wire Feeds Off Bottom Of Spool
Bad
Ref. 259144-C / 269 820-A
OM-276631 Page 23
5-15. Installing Welding Gun
1
2
3
4
5
Power Clamp Knob
Gun Locking Tab
Gun Locking Tab Rotated 180
Degrees
Power Pin Groove
Gun Connection End
Installing gun with Accu-Mate
connection
Loosen power clamp knob to allow
power pin of gun to clear the gun
locking tab.
Push power pin into power clamp
as far as possible to align the
groove in the power pin of the gun
with the gun locking tab.
5
Secure gun by tightening power
clamp knob.
Installing gun without AccuMate connection
When using a gun without the
groove in the power pin, loosen
power clamp knob and rotate gun
locking tab 180 degrees. This prevents the locking tab from extending into the power pin gun connection.
4
Installing gun with
Accu-Mate connection
1
Installing gun without
Accu-Mate connection
1
2
Push power pin into power clamp
as far as possible.
3
Secure gun by tightening power
clamp knob.
6
Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
6
Ref. 301195−tp1 / 270 026-A / Ref. 260233-B
OM-276631 Page 24
5-16. Installing Wire Guides And Drive Rolls
6
7
8
1
9
10
11
5
4
3
Ref. 260233-B / 269 820-A
2
Installing Wire Guide And Drive Rolls
1 Drive Roll Tension Assembly
Open tension assembly.
2 Drive Roll Bracket Screw
3 Drive Roll Bracket
4 Drive Roll Carrier And Securing Ring
Remove bracket screw.
Remove drive roll bracket.
5 Drive Roll
Rotate securing rings until tabs line up with
grooves in drive rolls. Remove drive rolls
from carriers.
6 Ball And Spring Assembly
7 Anti-Wear Guide
8 Inlet Wire Guide
9 Thumb Screw
Install inlet wire guide into anti-wear guide,
and secure with setscrew.
Loosen thumb screw.
Push inlet guide into opening until groove
aligns with thumb screw. Tighten thumb
screw to secure inlet guide.
10 Intermediate Wire Guide
. Shoulder on intermediate wire guide
faces to rear of drive housing.
Push intermediate guide into opening until
groove is secured by ball and spring
assembly.
Install drive rolls and drive roll bracket.
Secure bracket with screw.
11 Upper Drive Roll Shaft
Pull drive roll shaft and remove drive roll
carrier. Install drive roll, rotate securing ring
until it stops at a detent position, place carrier back into tension assembly bracket,
and secure carrier with drive roll shaft. Do
the same for the remaining tension
assembly.
. Never close Tension Assembly if Drive
Roll Bracket (3) is removed.
Aligning Wire Guide And Drive Rolls
Self-aligning drive rolls do not require any
manual adjustment.
Cleaning Drive Rolls
Remove drive rolls, and clean grooves
using a wire brush.
Close drive assembly cover.
OM-276631 Page 25
5-17. Installing And Threading Welding Wire
Tools Needed:
Install wire guides and
anti-wear guide.
Install drive rolls.
. Hold wire tightly to keep it from unraveling.
6 in.
(150 mm)
Pull and hold wire; cut off end.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Back Of Gun
Drive Rolls
Pressure
Adjust
Pressure
Indicator
Scale
End Of Liner
No Wire Slip
NONCONDUCTIVE
SURFACE
. For best wire feeding performance, be
sure that the outlet cable has the proper
size liner for the welding wire size being
used. Also, when the gun is installed, the
liner extending from the back of the gun
should be as close to the drive rolls as
possible, without touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Wire Slips
NONCONDUCTIVE
SURFACE
. For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in. (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If
contact tip is completely blocked, wire
should slip at the feeder (see pressure
adjustment above).Cut wire off. Close
cover.
Ref. 156929-A / Ref. 259144-C / 242517-A
OM-276631 Page 26
Notes
OM-276631 Page 27
5-18. Wire Feeder User Interface
1
10
13
12
18
14
15
16
8
17
2
9
11
20
4
7
6
3
19
5
OM-276631 Page 28
Ref. 266 061-B
5-19. Description Of Front Panel Controls (See Section 5-18)
1 Memory Display
The Memory display shows the active weld
program. The range is from 0001 to 9999.
2 Memory/Variable Adjustment Knob
Use this knob to select a program number
or increase/decrease the variable shown in
the Memory display.
3 Arc Control Button
The Arc Control button is process dependent. It allows user to change the variable
that appears on the Values/Parameters display, such as inductance, DIG, RMD (ball
size) or trim. The range can be +/− depending on the process.
4 Memory 1-8 Buttons And LEDs
Use these buttons to select a stored
program from the weld program library data.
The LED will indicate which program is
selected and active.
The Variables/Parameters display will
show weld program library summary data
for the selected program.
5 Soft Key Buttons
Use these buttons to navigate the menus
appearing in the LCD display (See Section
5-21).
6 Scroll Knob And Select/Save Button
Rotate this knob to scroll available options
or increase/decrease the variable shown in
the LCD display.
Pressing this knob acts as a Select/Save
button. Press the button to select options
available in the LCD display
7 Values/Parameters LCD Display
This display shows all values and parameters that have been selected using the Soft
Key buttons and the Scroll knob and Save/
Select button.
8 Amperage/Wire Feed Speed Display
This display shows amperage, or wire feed
speed depending on the process selected.
9 Amperage/Wire Feed Speed/Material
Thickness Adjustment Knob
Use this knob to increase/decrease amperage, wire feed speed, or material thickness
depending on the process selection. These
values appear on the Amperage/Wire Feed
Speed/Material Thickness display.
10 Voltage/Arc Length/Inductance/Arc
Adjust/RMD Display
This display shows voltage, arc length, inductance, arc adjust or RMD depending on
the process selected.
11 Voltage/Arc Control Adjustment Knob
Use this knob to increase/decrease voltage
or arc length depending on the process selection. These values appear on the
Voltage/Arc Length/Inductance/Arc Adjust/
RMD display.
12 Arc Length Indicator
LED illuminates to show that arc length
function is active.
13 Voltage Indicator
LED illuminates to show that the voltage
function is active.
14 Synergic Mode Active Indicator
LED illuminates to show that a synergic
weld process is active.
15 Amperage Indicator
LED illuminates to show that a SMAW,
GMAW or CAG process is selected. Values
appear on the Voltage/Arc Length/Inductance/Arc Adjust/RMD display.
16 Wire Feed Speed Indicator
LED illuminates to show that a GMAW or
GMAW-P weld process is selected. Values
appear on the Amperage/Wire Feed Speed/
Material Thickness display.
17 Material Thickness Indicator
This feature will be functional in a later software release.
18 Output ON Indicator
LED illuminates to show that open circuit
voltage is present at the weld output terminals.
19 USB Port
Use this port for all USB related functions
(See Section 5-31).
20 Parameter Lock Indicator
LED illuminates to show weld parameters
are locked and active.
* Disabled or not available.
OM-276631 Page 29
5-20. Wire Feeder Lower Panel Controls
1
6
3
2
4
5
258 508-B
1
Cold Wire Jog Button
Allows the operator to feed wire through
gun when changing wire spools. Weld output remains off while using cold wire jog
button.
2
Trigger Control Button
Allows operator to cycle through different
trigger options. See Section 5-26.
OM-276631 Page 30
3 TH Indicator
Trigger Hold (TH) allows the operator to
start a welding operation by pressing the
gun trigger and holding for a preset time
period (see Setup Menu features). After
the set time elapses the trigger latches and
the operator can release the trigger and the
welding operation will continue. When the
operator presses and releases the trigger,
the welding operation will discontinue.
4 Purge Button
Allows operator to purge gas line. To
change amount of purge time (See Section
5-27).
5 Water Supply Quick Connect Fitting
(CE Model only)
6 Water Return Quick Connect Fitting
(CE Model only)
5-21. LCD Home Screen
1
Directory Indicator
Displays the directory path of current
screen.
2
9
8
3
Home
1
Internet
WiFi
3
Setup
Logs
Ethernet
Status
Program Information
Displays the process type, wire diameter,
wire type and alloy, and gas mixture assigned to the current weld program.
Program # 1
Accupulse
.035 Steel E70
Ar 90 CO2 10
2
Program Number
Displays the current weld program
number.
4
Setup Soft Key
Press Setup soft key to enter the Setup
menu screen. Setup Menu screen allows
weld programs to be created or changed.
For more information see Section 5-22.
5
Logs Soft Key
Press Logs soft key to enter Logs menu
screen. For more information
see Section 5-23.
System
6
Status Soft Key
Press Status soft key to enter the Status
menu screen. For more information see
Section 5-24.
4
5
6
7
7
System Soft Key
Press System Soft Key to enter System
menu screen. System menu allows access
to System Reset, USB, and board software
revision functions. For more information
see Section 5-29.
8
Network Connection Indicator
Displays the type of network connection
being used.
Ref 266 061-A
9
Internet
Displayed when Insight Core is enabled.
5-22. Setup Menu
1
Directory Indicator
Displays the current directory path.
2
Menu Name
Displays the current menu name.
3
1
Home > Setup
Setup Menu
2
4
Load New Process
Trigger Configuration
Weld Sequence Configuration
Feedback Configuration
Options
Load New Process− Add or make changes to a
weld program. See Section 5-25.
4
3
Home
Scroll Knob and Select/Save Button
Rotate knob to change active option. Active option will have black circle next to it while inactive
options will be white. Press the knob to select the
active option.
Back
Trigger Configuration- Select and edit dual
schedule, trigger dual schedule, 4T, and trigger
hold features. See Section 5-26.
Weld Sequence Configuration- Change different
aspects of the weld sequence such as preflow,
start amperage, crater, and post flow.
See Section 5-27.
Feedback Configuration- Set voltage feedback
method to stud sense or sense lead. See Section
5-28.
5
5
Home Soft Key
Press Home soft key to return to Home menu
screen.
Ref 266 061-A
OM-276631 Page 31
5-23. Logs Menu
1
Directory Indicator
Displays the current directory path.
2
Menu Name
Displays the current menu name.
3
Rotate knob to change active option.
Active option will have black circle next
to it while inactive options will be white.
Press the knob to select the active
option.
Home > Logs
1
Logs Menu
2
Scroll Knob and Select/Save
Button
Error Log
Boot Log
4
4
3
Home
Options
Error Log− Displays a list of the last errors the unit has detected. Use the
Scroll Knob to scroll through the list.
From the Error log screen press the
Home soft key to return to the Home
screen, or the Logs Soft key to return to
the Logs Menu.
Back
Boot Log− Displays the sequence and
status of events that occurred during the
boot process.
5
5
Home Soft Key
Press Home soft key to return to Home
menu screen.
Ref 266 061-A
5-24. Status Menu
1
Directory Indicator
Displays the current directory path.
2
Menu Name
Displays the current menu name.
3
1
Home > Status
Status Menu
2
4
Load Bank Mode> Off
Accu‐Power Mode> Off
Actual / Command> Off
Options
Load Bank Mode- Used to calibrate meters
or test equipment when servicing.
4
3
Home
Scroll Knob and Select/Save Button
Rotate knob to change active option. Active
option will have black circle next to it while inactive options will be white. Press the knob
to select the active
option.
Back
5
Accu-Power Mode- Displays instantaneous
power on wire feed speed display in kilojoules per second to the nearest tenth, updated once per second while welding. After
the weld, instantaneous power is displayed
for approximately ten seconds before the
display changes back to wire feed speed. If
wire feed speed is adjusted during the weld
operation, the display will show wire feed
speed while being adjusted and will revert
back to instantaneous power after adjustment has been made.
To calculate weld heat input, multiply the instantaneous power by the arc time then divide by weld bead length, see equation.
HeatInput[kJńin(kJńmm)] +
Power(kJńs)xArcTime(s)
WeldBeadLength[in(mm)]
Actual / Command− Values displayed while
welding can can be set to display either actual values or command values set by user.
5
Home Soft Key
Press Home soft key to return to Home
menu screen.
Ref 266 061-A
OM-276631 Page 32
5-25. Creating, Changing And Saving a Weld Program
At the Home screen, using either the
memory adjustment knob or memory
buttons, select the program number to
be used.
From the Home screen, press the Setup
softkey.
In the Setup menu rotate the scroll knob
to make Load New Process the active
option. Press the knob to select Load
New Process.
Home > Setup
Setup Menu
Follow screen prompts.
Load New Process
Trigger Configuration
Weld Sequence Configuration
Feedback Configuration
Step 1- Select Wire Type
Step 2- Select Wire Alloy
Step 3- Select Wire Size
Step 4- Select Gas Mixture
Step 5- Select Process
Home
Back
After selecting process, the display will
read Process Loading. At 100% the program is saved and ready to use.
Ref 266 061-A
5-26. Trigger Configuration
In the Setup menu, rotate the scroll knob
to make Trigger Configuration the active
option. Press the scroll knob to select
Trigger Configuration.
. All programs are paired in numeri-
cal order for dual schedule functions. Program 1 and 2 are paired,
program 3 and 4 are paired, etc.
Home > Setup > Trigger Config
Program # 1
Program # 2
Dual Schedule
Dual Schedule
Trigger Dual Schedule
Trigger Dual Schedule
Trigger Program Select
Trigger Program Select
4T
4T
Trigger Hold
Trigger Hold
Home
Setup
Select desired trigger function using the
scroll knob.
Edit
Ref 266 061-A
OM-276631 Page 33
5-27. Weld Sequence Configuration
At the Home screen, use either the
memory adjustment knob or memory
buttons to select the program number to
be changed.
From the Home screen, press the Setup
softkey.
In the Setup menu, rotate the scroll knob
to make Weld Sequence Configuration
the active option. Press the scroll knob
to select Weld Sequence Configuration.
Home > Setup > Sequence
Sequence Select ‐ Program 1
Preflow ‐
Start ‐
Start Ramp ‐
Weld ‐
Crater Ramp ‐
Crater ‐
Retract ‐
Postflow ‐
Setup
Home
In the weld sequence configuration
screen, rotate the scroll knob to desired
function. Press the scroll knob to either
enable or disable the function.
Disabled
Disabled
Disabled
Enabled
Disabled
Disabled
Disabled
Disabled
With the desired function active, press
the Edit softkey to change the functions
corresponding parameters:
Preflow- Adjust the length of time gas
flows before weld begins.
Edit
Start- Adjust voltage, wirefeed speed,
time and inductance used for starting
weld.
Start Ramp- Adjust the length of time
weld takes from start to weld parameters.
Weld- Adjust the voltage, wirefeed
speed, time, and inductance.
Crater Ramp- Adjust the length of time
from weld to crater parameters.
Crater- Adjust the voltage, wirefeed
speed, time, and inductance for crater
settings.
Retract- Set the speed and the amount
of time the wire retracts after weld.
Postflow- Adjust the amount of time gas
flows after the weld.
Weld
Crater
Time
Preflow
Time
Retract
Time
Start
Time
Postflow
Time
Time
Preflow
Trigger
Pressed
Start
Weld
Crater
Retract
Postflow Sequence
End
Trigger
Released
Ref 266 061-A
OM-276631 Page 34
5-28. Feedback Configuration
1
Directory Indicator
Displays the current directory path.
2
Menu Name
Displays the current menu name.
3
Active Indicator
Displays the active feedback method.
1
2
3
Home > Setup > Feedback Configuration
4
Feedback Configuration
Active >
Rotate knob to change active option.
Active option will have black circle next
to it while inactive options will be white.
Press the knob to select the active
option.
Sense Lead
Change voltage feedback method:
Stud Sense
Sense Lead
4
5
Home
Scroll Knob and Select/Save
Button
Back
5
Options
Stud Sense- Current feedback measurement is taken at the output studs of
the welding power source.
Sense Lead- Current feedback measurement is taken with a volt sense lead.
6
Home Soft Key
Press Home soft key to return to Home
menu screen.
6
Ref 266 061-A
5-29. System Menu
1
Directory Indicator
Displays the current directory path.
2
Menu Name
Displays the current menu name.
3
1
Home > System
4
Rotate knob to change active option.
Active option will have black circle next
to it while inactive options will be white.
Press the knob to select the active
option.
System Menu
2
Factory Reset
USB Functions
System Software Revision
Network Settings
Machine Serial Number
Home
Scroll Knob and Select/Save
Button
4
3
Back
Options
Factory Reset- Allows user to reset all
values to factory defaults (See Section
5-30).
USB Functions- Update software and
load or save weld programs with a USB
(See Section 5-31).
System Software Revision- Displays
the current software revision of the
welding system.
5
Network Settings- Displays information
about the network connections such as
IP Address.
Machine Serial Number- Displays the
serial number of the unit.
5
Home Soft Key
Press Home soft key to return to Home
menu screen.
Ref 266 061-A
OM-276631 Page 35
5-30. Factory Reset
From the Home screen, press the
System softkey.
In the System menu rotate the scroll
knob to make Factory Reset the active
option. Press the knob to select Factory
Reset.
Home > System > Factory Reset
At the Factory Reset screen rotate the
scroll knob to select Yes. Press the
scroll knob to perform a Factory Reset.
Factory Reset
Perform Factory Reset?
Display will return to the Home screen
when Factory Reset is complete.
No
Yes
Home
Back
Ref 266 061-A
5-31. USB Functions
From the Home screen, press the System softkey.
Home > System > USB
USB Functions
Write to system
Write to USB
In the System menu rotate the scroll
knob to make USB Functions the active
option. Press the knob to select USB
Functions.
Options
Write to system- Use a USB key to update unit software and weld programs.
Write to USBSystem Settings− Save user created
weld programs to a USB key. User settings can then be loaded on other units,
or restored on the current unit.
Home
System
License Key− Available in Insight Core
enabled units. Save license key to USB
when registering Insight Core.
Diagnostic Files−Available in Insight
Core enabled units. Save diagnostic
files to be sent back to Miller Service
Representatives.
Ref 266 061-A
OM-276631 Page 36
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
Reference
l Unreadable Labels
~ Weld Terminals
nl Weld Cables
nl Gun Cables
nl Cords
nl Cracked Parts
~ Weld Connections
n Tighten Weld Cable
Connections
Every
3
Months
l Damaged Gas Hose
Every
6
Months
OR
~ Drive Rolls
~ Inside Unit
Notes
OM-276631 Page 37
6-2. Error Code Troubleshooting Description And Tables
1
ERR
BTN
2
STUK
ERROR
3
4
Button on UI stuck
Make sure all buttons are clear
If error persists, please contact support.
Logs
5
Ref. 266 061-B
1
LED Display Message
Displays a short message describing the
error or where the error is occurring. Some
messages may represent multiple different
errors. For more specific error information
see the LCD Display Message.
2
Message Type
There are three types of messages that will
be displayed.
OM-276631 Page 38
ERROR- The system has experienced a
fault that must be addressed before continuing use.
MESSAGE- No fault has occurred, but
some action must be taken before resuming use of the welding system. For
instance, input power may need to be
cycled after loading new software.
WARNING- There is something that
should be addressed before continuing.
For instance, the volt sense lead connection has been lost.
3 LCD Display Message
Provides more information about the message being displayed.
4 LCD Solution Message
Describes the action needed to clear the
message or fault being experienced.
5 Logs Soft Key
Pressing the Logs soft key will take the user to the Logs Menu (See Section 5-23).
From the Logs Menu it is possible to access the Error Log. The LCD Error Log
Messages are stored in the Error Log.
LED Display
Message
WELD
WAIT
Message
Type
LCD Display Message
LCD Solution
Message
LCD Error Log
Message
ERROR
Unit was not ready for a weld sequence
Press button to clear error
Weld Wait Error
ERROR
Welding power source has overheated
Allow unit too cool then cycle
power
Overtemp Error
ERROR
Emergency stop activated
Reset the emergency stop
button
E Stop
OVER CURRENT
ERROR
Welding power source primary draw
too high
Check input primary then cycle power
Primary Overcurrent
CYCLE POWER
MESSAGE
The unit requires a power cycle
Cycle power on the power
source
Cycle Power Error
ERR OVERTEMP
E STOP
OVER POWER
ERROR
SLF TST ERR
ERROR
Welder failed self test
Cycle power on the power
source
Self Test Error
ERR INPT PWR
ERROR
Input Power Problem
Ensure your primary voltage is
correct
Input Power Problem
ERR
ERROR
Feeder Power Problem
Cycle power on the power
source
Feeder Power Problem
ERR AUX PWR
ERROR
AUX Power Problem
Cycle power on the power
source
AUX Power Problem
ERR
ERROR
Thermal System Problem
Cycle power on the power
source
Thermal System Problem
ERR PWR SRC
ERROR
Welder Power Source Problem
Cycle power on the power
source
Power Source Problem
ERR
WFS
ERROR
Actual WFS does not match command
Press button to clear error
Wire Speed Error
ERR
STRT
ERROR
Trigger held too long without arc
Press button to clear error
Arc Start Error
ERR
STOP
ERROR
Potential obstruction in wire feed system
Check wire feed and wire
drive systems
Arc Stop Error
ERR GAS FLW
ERROR
No gas flow to the gun
Check gas connections
Gas Flow Error
ERR COOL FLW
ERROR
No coolant flow in water system
Check water cooling system
Coolant Flow Error
ERR GND CRNT
ERROR
Weld current detected in earth ground
Check and repair feeder weld
connections
Earth Ground Current Error
ERR WIR STUK
ERROR
Wire stick to workpiece at the end of
the weld
Break/Cut wire away from
workpiece
Wire Stuck Error
ERR
ERROR
Arc Outage occurred
Check wire feeder and power
source
Arc Outage Error
ERR TRG STUK
ERROR
Trigger held during power up
Release trigger and cycle
power
Trigger Stuck Error
ERR SOFTWARE
ERROR
Incompatible software detected in the
system
Update software
Incompatible Software Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder EEPROM Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder USART1 Error
ERR COMM FDR
ERROR
Feeder Lost Comms to Arc Controller
Check the control cable
Feeder lost comms to AC
ERR FDR PWR
ERROR
Feeder power fault
Cycle power on the power
source
Feeder bus overcurrent error
ERR FDR PWR
ERROR
Feeder power fault
Cycle power on the power
source
Feeder bus current fault
ERR FDR RLY
ERROR
Feeder power relay stuck open
Cycle power on the power
source
Feeder relay stuck open
ERR FDR ETH
ERROR
Feeder Ethernet switch malfunction
Cycle power on the power
source
Feeder Ethernet switch error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder USART3 Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder USART2 Error
ERR FEEDER
ERROR
Feeder peripheral malfunction
Cycle power on the power
source
Feeder SPI2 Error
ERR FDR TACH
ERROR
Feeder has lost tachometer wire
speed feedback
FDR
THERM
ARC
Feeder lost tach signal error
OM-276631 Page 39
LED Display
Message
Message
Type
LCD Display Message
LCD Solution
Message
LCD Error Log
Message
ERR BTN STUK
ERROR
Button on UI stuck
Make sure all buttons are
clear
UI Button Stuck
ERR COMM UI
ERROR
UI Lost Comms to the Sequencer
Check the control cable
UI lost comms to Seq
FACTORY RST
ERROR
Factory Reset Complete
Cycle power on the power
source
Factory Reset
UNUSED 218
ERROR
Unused Error #218
Cycle power on the power
source
Unused Error #218
ERR INPT PWR
ERROR
Must use three phase primary power
Check primary connections
Single Phase Error
ERR INPT PWR
ERROR
Primary input voltage too high
Check primary connections
High Input Voltage Error
ERR INPT PWR
ERROR
Primary input voltage too low
Check primary connections
Low Input Voltage Error
UNUSED 222
ERROR
Unused Error #222
Cycle power on the power
source
Unused Error #222
ERR FEEDER
ERROR
Feeder input voltage too high
Cycle power on the power
source
Feeder Voltage High Error
ERR FEEDER
ERROR
Feeder input voltage too low
Cycle power on the power
source
Feeder Voltage Low Error
UNUSED 225
ERROR
Unused Error #225
Cycle power on the power
source
Unused Error #225
ERR AUX PWR
ERROR
Too much current draw from AUX
power port
Cycle power on the power
source
AUX Power Overcurrent Error
ERR AUX PWR
ERROR
AUX power module overheated
Cycle power on the power
source
AUX Power Overtemp Error
ERR AUX PWR
ERROR
AUX power voltage too high
Cycle power on the power
source
AUX Voltage High Error
ERR AUX PWR
ERROR
AUX power voltage too low
Cycle power on the power
source
AUX Voltage Low Error
UNUSED 230
ERROR
Unused Error #230
Cycle power on the power
source
Unused Error #230
ERR THERM 1
ERROR
Thermistor 1 overtemp
Allow welder to cool then cycle power
THERM1 Overtemp Error
ERR THERM 2
ERROR
Thermistor 2 overtemp
Allow welder to cool then cycle power
THERM2 Overtemp Error
ERR THERM 3
ERROR
Thermistor 3 overtemp
Allow welder to cool then cycle power
THERM3 Overtemp Error
ERR THERM 1
ERROR
Thermistor 1 shorted
Cycle power on the power
source
THERM1 Shorted Error
ERR THERM 2
ERROR
Thermistor 2 shorted
Cycle power on the power
source
THERM2 Shorted Error
ERR THERM 3
ERROR
Thermistor 3 shorted
Cycle power on the power
source
THERM3 Shorted Error
ERR THERM 1
ERROR
Thermistor 1 open
Cycle power on the power
source
THERM1 Open Error
ERR THERM 2
ERROR
Thermistor 2 open
Cycle power on the power
source
THERM2 Open Error
ERR THERM 3
ERROR
Thermistor 3 open
Cycle power on the power
source
THERM3 Open Error
ERR PWR SRC
ERROR
Invalid device configuration
Cycle power on the power
source
Invalid Power Source Config
ERR PWR SRC
ERROR
Output current sensor malfunction
Cycle power on the power
source
Output Current Sensor Error
ERR PWR SRC
ERROR
Inverter −15V power supply out of regulation
Cycle power on the power
source
Inverter −15V Power Error
ERR PWR SRC
ERROR
Inverter +15V power supply out of regulation
Cycle power on the power
source
Inverter +15V Power Error
ERR PWR SRC
ERROR
Invalid inverter device configuration
Cycle power on the power
source
Invalid Inverter Config
ERR PWR SRC
ERROR
Inverter primary CT error
Cycle power on the power
source
Inverter Primary CT Error
ERR PWR SRC
ERROR
Boost fault
Cycle power on the power
source
Boost Fault Error
OM-276631 Page 40
LED Display
Message
Message
Type
LCD Solution
Message
LCD Display Message
LCD Error Log
Message
ERR PWR SRC
ERROR
Boost contactor error
Cycle power on the power
source
Boost Contactor Error
ERR PWR SRC
ERROR
Boost CS1 current error
Cycle power on the power
source
Boost CS1 Error
ERR PWR SRC
ERROR
Boost CS2 current error
Cycle power on the power
source
Boost CS2 Error
ERR PWR SRC
ERROR
Boost CS3 current error
Cycle power on the power
source
Boost CS3 Error
ERR PWR SRC
ERROR
Boost CS4 current error
Cycle power on the power
source
Boost CS4 Error
ERR PWR SRC
ERROR
Boost current balance error
Cycle power on the power
source
Boost Current Balance Error
ERR PWR SRC
ERROR
Boost overcurrent error
Cycle power on the power
source
Boost Overcurrent Error
ERR PWR SRC
ERROR
Boost precharge error
Cycle power on the power
source
Boost Precharge Error
ERR PWR SRC
ERROR
Boost bus balance error
Cycle power on the power
source
Boost Bus Balance Error
ERR PWR SRC
ERROR
Boost bottom bus cap voltage high
Cycle power on the power
source
Boost Bottom Bus Cap V High
ERR PWR SRC
ERROR
Boost top bus cap voltage high
Cycle power on the power
source
Boost Top Bus Cap V High
ERR PWR SRC
ERROR
Invalid boost device configuration
Cycle power on the power
source
Invalid Boost Config
ERR PWR SRC
ERROR
Boost −15V power supply out of regulation
Cycle power on the power
source
Boost −15V Power Error
ERR PWR SRC
ERROR
Boost −24V power supply out of regulation
Cycle power on the power
source
Boost −24V Power Error
ERR PWR SRC
ERROR
Boost +15V power supply out of regulation
Cycle power on the power
source
Boost +15V Power Error
WRN VSNS LOS
WARNING
Lost volt sense lead feedback
Inspect volt sense lead for
break
Vsense Fallback Warning
ERR UNKNOWN
ERROR
An unknown error has occurred
Update software
Unknown Error
6-3. Troubleshooting
!
Trouble
Disconnect power before troubleshooting
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check and secure weld cable connections (see Section 5-4).
Electrode wire feeding stops or feeds
erratically during welding.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 5-17).
Change to correct size drive roll (see Section 5-16).
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-276631 Page 41
SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram
OM-276631 Page 42
274364-B
OM-276431 Page 43
SECTION 8 − PARTS LIST
. Hardware is common and
9
not available unless listed.
8
38
7
38
4
34
6
36
35
43
41
37
42
33
3
5
11 - Figure 8-3
2
1
23
10 - Figure 8-2
12 Figure 8-6
39
13 - Figure 8-4
14
24
40
28 27
26
32 31
27 28
30
26
25
15
29
22
16
21
17
20
Figure 8-1. Main Assembly
OM-276631 Page 44
19
18
277158-B
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
CE
Non
Figure 8-1. Main Assembly
Model
CE
. . 1 . . . . . . . . . . . . . . 266419 . . Base, Feeder Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 2 . . . . . . . . . . . . . . 266181 . . Support, A−Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 3 . . . . . . . . . . . . . . 257227 . . Bracket, Support A−Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 4 . . . . . . . . . . . . . +269642 . . Door, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 5 . . . . . . . . . . . . . . 270991 . . Insulator, Mylar .014x5.000x9.000 . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 6 . . . . . . . . . . . . . . 275806 . . Label, Warning Hot Surfaces And Moving Parts . . . . . . . . . . . . . 1 . . . . . 1
. . 7 . . . . . . . . . . . . . . 269889 . . Label, Caution Pinch Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 8 . . . . . . . . . . . . . +269288 . . Wrapper, Feeder Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 9 . . . . . . . . . . . . . . 274964 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 10 . . . . . . . . . . +Figure 8-2 . . Panel Assy, Front Single 4 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 11 . . . . . . . . . . . . Figure 8-3 . . Panel Assy, Rear Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 12 . . . . . . . . . . . . Figure 8-6 . . Assy, UI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 13 . . . . . . . . . . . . Figure 8-4 . . Drive Assy, Wire Single Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 14 . . . . . . . . . . . . See Inset . . Assy, Power Pin Block Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 15 . . . . . . . . . . . . . . 073432 . . . . Ftg, Hose Brs Barbed M 3/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . 1 . . . . . 1
. . 16 . . . . . . . . . . . . . . 268570 . . . . Block, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 17 . . . . . . . . . . . . . . 234073 . . . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 18 . . . . . . . . . . . . . . 251557 . . . . Spring, Cprsn .210 Od X .026 Wire X 1.000 Pld . . . . . . . . . . . 1 . . . . . 1
. . 19 . . . . . . . . . . . . . . 262691 . . . . Clamp, Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 20 . . . . . . . . . . . . . . 262703 . . . . Lock, Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 21 . . . . . . . . . . . . . . 151437 . . . . Knob, T 1.500 Bar W/.312−18 Stud 1.125 Lg Plstc . . . . . . . 1 . . . . . 1
. . 22 . . . . . . . . . . . . . . 151828 . . . . Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 23 . . . . . . . . . . . . . . 257231 . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 24 . . . . . . . . . . . . . . 268704 . . Hub and Spindle Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 25 . . . . . . . . . . . . . . 265876 . . . . Shaft, Spool Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 26 . . . . . . . . . . . . . . 231211 . . . . Washer, Anti−Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 27 . . . . . . . . . . . . . . 010191 . . . . Washer, Flat .656idx1.500odx.125t Fbr . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 28 . . . . . . . . . . . . . . 058628 . . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 29 . . . . . . . . . . . . . . 058428 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 30 . . . . . . . . . . . . . . 058427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 31 . . . . . . . . . . . . . . 010233 . . . . Spring, Cprsn .970 Od X .120 Wire X 1.250 Pld . . . . . . . . . . 1 . . . . . 1
. . 32 . . . . . . . . . . . . . . 237843 . . . . Knob, Brake Adjust (Diecast) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 33 . . . . . . . . . . . . . . 089899 . . Latch, Slide Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 34 . . . . . . . . . . . . . . 269633 . . Bracket, Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 35 . . . . . . . . . . . . . . 276250 . . Bracket, Rear Grommet Cords/Cables (CE) . . . . . . . . . . . . . . . . . 0 . . . . . 1
. . 35 . . . . . . . . . . . . . . 262770 . . Bracket, Rear Grommet Cords/Cables . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 0
. . 36 . . . . . . . . . . . . . . 266397 . . Bushing, Snap−in Nyl 1.860 ID x 2.250 Dia Mtg Hole . . . . . . . . . 1 . . . . . 1
. . 37 . . . . . . . . . . . . . . 170647 . . Bushing, Snap−In Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . 2 . . . . . 2
. . 38 . . . . . . . . . . . . . . 267307 . . Hinge, Door Friction Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . 39 . . . . . S1 . . . . . 216295 . . Switch, Rocker SPDT .4VA 28VDC (On)-Off-(On) . . . . . . . . . . . . 1 . . . . . 1
. . 40 . . . . . . . . . . . . . . 267482 . . Bracket, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . 41 . . . . . . . . . . . . . . 274610 . . Cover, Spool 12 in (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 1
. . 42 . . . . . . . . . . . . . . 274611 . . Case, Spool 12 in (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 1
. . 43 . . . . . . . . . . . . . . 057357 . . Bushing, Snap−In Nyl .937 Id x 1.125 Mtg Hole . . . . . . . . . . . . . . 0 . . . . . 2
. . . . . . . . . . L22 . . . . 276360 . . Core, Ferrite 9.50mm Od X 4.75mm Id . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 1
. . . . . . . . . . L21 . . . . 276358 . . Core, Ferrite 25.90mm Od X 12.80mm Id . . . . . . . . . . . . . . . . . . . 0 . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-276631 Page 45
. Hardware is common and
10
not available unless listed.
8
6
11
5
9
1
7
2
4
3
277157-A
Figure 8-2. Front Panel Assembly
Item
No.
..
..
..
..
..
..
..
..
..
..
..
..
+
Dia.
Mkgs.
Part
No.
Description
Quantity
CE
Non
Figure 8-2. Front Panel Assembly (Figure 8-1, Item 10)
Model
CE
1 . . . . . . . . . . . . . . 256145 . . Plate, Trigger Single 4 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
2 . . . . . . . . . . . . . . 258507 . . Membrane, Switch Control Continuum Feeder Dual . . . . . . . . . . 0 . . . . . 1
2 . . . . . . . . . . . . . . 275629 . . Membrane, Switch Control Continuum Feeder Dual . . . . . . . . . . 1 . . . . . 0
3 . . . . . . . . . . . . . . 253528 . . Bezel, Feeder With Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
4 . . . . . . . . . . . . . . 223343 . . Clip, Wire Stdf .40−.50 Bndl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
5 . . . . . . . . . . . . . . 170647 . . Bushing, Snap−In Nyl 1.062 Id x 1.500 Mtg Hole Cent . . . . . . . . 2 . . . . . 2
6 . . . . . . . . . . . . . . 253628 . . Baffle, Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
7 . . . . . . . . . . . . . . 276277 . . Ftg, Water Quick Conn .187 Female Panel Mount . . . . . . . . . . . 0 . . . . . 2
8 . . . . PC32 . . . . 266149 . . Circuit Card Assy, Trigger Single 4 Pin . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
9 . . . . . . . . . . . . . . 207152 . . Nut, 010−32 U−Nut Multi Thread . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
10 . . . . . . . . . . . . . . 274994 . . Hose, Water 11 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 1
11 . . . . . . . . . . . . . . 274994 . . Hose, Water 12 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . 1
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-276631 Page 46
. Hardware is common and
not available unless listed.
7
6
5
8
9
10
8
1
3
2
4
277159-B
Figure 8-3. Rear Panel Assembly
Item
No.
..
..
..
..
..
..
..
..
..
..
+
1
2
3
4
5
6
7
8
9
10
Dia.
Mkgs.
Part
No.
Description
Quantity
CE
Non
Figure 8-3. Rear Panel Assembly (Figure 8-1, Item 11)
Model
CE
. . . . . . . . . . . . . . . . . . . . . . . . Label, Nameplate (Order By Model and Serial Number) . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . 211989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . 220805 . . Nut, .750 − 14 NPS 1.48 Hex .41H Nyl . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . 276278 . . Fitting, Water Quick Connect Male Panel Mount . . . . . . . . . . . . . 0 . . . . . 2
. . . . . . . . . . . . . . 269715 . . Stand−off Support, PC Card .312/.375 W/Post & Lock . . . . . . . 4 . . . . . 4
. . . . . . . . . . . . . . 253598 . . Panel, Rear Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . . PC31 . . . . 272939 . . Circuit Card Assy, Motor/Feeder Comm W/Prog . . . . . . . . . . . . . 1 . . . . . 1
. . . . . . . . . . . . . . 265352 . . Tubing, Polyurethane Blk .197 Id x .315 Od x 18.000 . . . . . . . . . 2 . . . . . 2
. . . . . . . . . . . . . . 279847 . . Ftg, Push To Conn Straight 5/16 In Od Tubing . . . . . . . . . . . . . . 1 . . . . . 1
. . . . GS1 . . . . 228035 . . Valve, 34Vdc 1 Way .750−14 Thd 2mm Orf 100 Psi . . . . . . . . . 1 . . . . . 1
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-276631 Page 47
. Hardware is common and
not available unless listed.
1
2
3
4
12
11
6
5
7
8
10
9 - Figure 8-5
269672-B
Figure 8-4. Wire Drive Assembly
Item
No.
Dia.
Mkgs.
Part
No.
267148
. . . 1 . . . . . . . . . . 279953
. . . . . . . . . . . . . . . . 261787
. . . 2 . . . M1 . . 250786
. . . 3 . . . . . . . . . . 251691
. . . 4 . . . . . . . . . . 253589
. . . 5 . . . . . . . . . . 267153
. . . 6 . . . . . . . . . . 266421
. . . 7 . . . . . . . . . . 267152
. . . 8 . . . . . . . . . . 267147
. . . 9 . . . . . . . . Figure 8-5
. . . 10 . . . . . . . . . . 263322
. . . 11 . . . . . . . . . . 256640
. . . 12 . . . . . . . . . . 266403
+
Description
Quantity
Figure 8-4. Wire Drive Assembly (Figure 8-1, Item 13)
. . Encoder, Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plug, w/Cable For Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/11HP 40VDC Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand-off, 10-32 X 1.250 Lg .313 Hex Stl M&M . . . . . . . . . . . . . . . . . . . . . . .
. . Hub, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Drive Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Al .166 Id X .250 Od X .562 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plate, Drive Mtg Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Motor Mount Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Drive Assy, Wire No Motor Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Thumb Stl .250−20 x .500 Pld Nylon Head . . . . . . . . . . . . . . . . . . . .
. . Block, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Retractable Spring Plunger Plate Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
1
1
3
1
1
1
1
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-276631 Page 48
. Hardware is common and
1
not available unless listed.
3
13
2
10
8
5
6
4
12
9
7
11
269727-A
Figure 8-5. Drive Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-5. Drive Assembly (Figure 8-4, Item 9)
..
..
..
..
..
..
..
..
..
..
..
..
..
+
1
2
3
4
5
6
7
8
9
10
11
12
13
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
260262
260263
259150
256877
261793
266830
260239
252217
251473
258383
263359
260260
151828
..
..
..
..
..
..
..
..
..
..
..
..
..
Assy, Pressure Arm Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assy, Pressure Arm Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring,Double Torsion .408 OD .051 Wire . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, Gear Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, Clevis .250 OD X 2.500 Lg W/Groove . . . . . . . . . . . . . . . . . . . . . . . . .
Carrier, Drive Roll W/Cmpnts 24 Pitch .250 In Shaft . . . . . . . . . . . . . . . . . .
Drive Body Assy, Cast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob Assy, Tension Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, Thumb Stl .312-18 X 1.500 Pld Nylon Head . . . . . . . . . . . . . . . . . .
Shaft Assy, Support Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
4
1
2
1
2
1
1
2
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-276631 Page 49
5
. Hardware is common and
not available unless listed.
1
3
2
4
6
8
7
269786-B
Figure 8-6. User Interface
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-6. User Interface (Figure 8-1, Item 12)
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
..........
..........
..........
..........
. . PC34 .
..........
..........
..........
266072
266061
266189
266591
272938
230052
269555
267343
. . Plate, Ui . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Membrane, Switch Control Continuum Ui . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Display, Lcd Tft 320x240 18bit Rgb Pc Tail . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, Encoder 1.250 Dia X 6mm Id Push On W/Spring . . . . . . . . . . . . . . .
. . Circuit Card Assy, Ui W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, .840 Dia X 6mm Id W/Spring Clip−4.5 . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, .840 Dia X 6mm Id W/Spring Clip−4.5 w/Print . . . . . . . . . . . . . . . . . .
. . Cover, USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-276631 Page 50
Table 8-1. Drive Roll And Wire Guide Kits
OM-276631 Page 51
Inlet Guide
221030
221030
221030
229919
229919
Wire Sizes
.023 to .040 in. (0.6 to 1.0mm)
.045 to .052 in. (1.1 to 1.4mm)
1/16 to 5/64 in. (1.6 to 2mm)
3/32 to 7/64 in. (2.4 to 2.8mm)
1/8 in. (3.2mm)
Wire Guides
*Accommodates .045 and .047 (3/64 in) wire
**Requires a low *speed wire feeder
149522
149521
149520
149519
149518
Intermediate Guide
151042
151043**
151076**
151075
151074
151073
151072
151071
151070
”U” COGGED FOR
EXTREMELY SOFT
WIRE OR SOFT*
SHELLED CORED
WIRES
1/16 in. (1.6mm)
.047 in. (1.2mm)
.035 in. (0.9mm)
Wire Size
221912
221912
221912
Inlet Guide
Nylon Wire Guides for Feeding Aluminum Wire
151060**
151059
151058
1/8 in. (3.2 mm)
151055
7/64 in. (2.8 mm)
151039
151054
151053
151041
151029
1/16 in. (1.6 mm)
151038
151037*
3/32 in. (2.4 mm)
151028
.052 in. (1.3/1.4 mm)
151057
151027
.045 in. (1.1/1.2 mm)
151040
161190
.040 in. (1.0 mm)
151052
5/64 in. (2.0 mm)
151026
.035 in. (0.9 mm)
”V” KNURLED FOR
HARD*SHELLED
CORED WIRES
151056
151025
.030 in. (0.8 mm)
”U” GROOVE FOR
SOFT*SHELLED
CORED WIRES
.068/.072 in. (1.8 mm)
151024
.023/.025 in. (0.6 mm)
WIRE SIZE
”V” GROOVE FOR
HARD WIRE
205937
205936
242417
Intermediate Guide
243235
243234*
243233
”U” GROOVE FOR
ALUMINUM WIRES
CONTAINS NYLON
WIRE GUIDES
Notes
Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective date of
6.
90
Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
* Canvas Covers
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
* Induction Heating Coils and Blankets, Cables, and
FITNESS.
Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any
* M-Guns
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
*
Remote
Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed below
in the event of such a failure within the warranty time periods. All
warranty time periods start on the delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2017-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2017 Miller Electric Mfg. Co.
2017−01
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