OM-2227 April Millerfi 197030 2000 Processes MIG The Power fBlue. (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source Deltashipfi 502 0 ~/ OWNERS IIl~ Visit www our website at MillerWelds corn MANUAL S S SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING - som Symbol UØage 1-1. Means 4A A The There possible are are of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. This group special safety message. a Arc I ~2. Out! procedure! The possible hazards adjoining symbols. shown in the Marks Watch Warning! hazards with this UT Means Note~ A not related. safety symbols I Hazards Welding are used throughout this manual identify possible hazards. When you If earth shown below to call attention to and with symbol, watch out, and follow the related instructions safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards. seethe A Only qualified persons repair this unit. A During operation, keep everybody, especially children, away. should a grounding or another electrode from safety Wear a Keep all and worktable as near Do not touch live electrical Wear S Insulate hole-free dry, there is a Use AC If AC of output and required, areas, if movement is confined, or the weld required use for the remote welding more than on output present and ground this equipment according to its S If ventilation is poor, use an S Read Safety the Material manufacturers be hazardous. a When Do not weld in locations making input connections, attach proper grounding double-check connections. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. - - Turn off all equipment Do not worn, when not in over your body. poorly spliced cables. to approved air-supplied respirator. (MSDS5) Data Sheets and the consumables, coatings, confined space near degreasing, cleaning, operations. The heat and rays of the arc form highly toxic and irritating gases. Do not weld on coated plated steel, weld area, the or arc only if it is well ventilated, or while 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. cadmium use. damaged, undersized, exhaust at the cleaners, and degreasers. an cables can use instructions for metals, wearing - drape work cable to any or head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or remove welding fumes and gases. on 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. Do not electrode fumes and gases. Breathing these fumes and gases can be hazardous to your health. Work in use one inverters. Manual and national, state, and local codes. - workpiece to prevent to Welding produces Keep your process. control if input power or stop engine before installing or equipment. Lockout/tagout input power according OSHA 29 CFR 191 0.147 (see Safety Standards). conductor first workpiece practical. as FUMES AND GASES if this Properly install place. body protection. Disconnect Owners in inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. unit. servicing securely metal-to-metal contact to falling. output ONLY if is good Turn Off I output in damp danger above floor level. working SIGNIFICANT DC VOLTAGE exists after removal of input power ~ Do not useAC ground, output terminal. weld ground using dry insulating mats prevent any physical contact with the to are different machine. parts. insulating gloves big enough ground. or single yourself from work and or covers work in contact with the work, required, ground clamp when not connected object. Do not connect 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. S directly is contact with any metal live Touching a covers cable with Insulate work kill. harness if panels Clamp work or can it workpiece Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. install, operate, maintain, and ELECTRIC SHOCK of the separate cable. Do not touch electrode if you to avoid the hazard. The to _nd_4198 area metals, such unless the is well can as coating or spraying react with vapors to galvanized, lead, or is removed from the ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-2227 Page 1 BUILDUP OF GAS ARC RAYS can bum eyes and skin Shut off 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. can injure or when not in shielding gas supply confined ventilate spaces Always approved air-supplied respirator. awelding helmet fitted with a propershade offilterto protect welding or watching (see ANSI Z49. 1 Z87.1 listed in Safety Standards). kill use. or use Wear your face and eyes when and Wear HOT PARTS can cause severe burns with side shields under your approved safety glasses helmet. Do not touch hot Use Allow protective screens or barriers to protect others from flash and others not to watch the glare; warn Wear protective clothing made from durable, flame-resistant (leather and wool) and foot protection. parts bare handed. before cooling period working on gun or torch. arc. material MAGNETIC FIELDS can affect pacemakers. WELDING can cause fire or explosion. Pacemaker wearers keep away. Wearers should consult their doctor before closed containers, such as tanks, 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. Protect Welding on drums, pipes, yourself or and others from flying sparks going near arc welding, gouging, welding operations. NOISE can flying sparks can Remove all flammables within 35 ft this is not possible, tightly cover strike flammable material. (10.7 m) them with Be aware that can cause fire Do not weld on keep welding on a fire of the welding arc. approved covers. closed containers such as Connect work cable to the work unknown Do not prevent welding paths and as causing tip when not in Wear approved CYLINDERS or ear protection if or can explode ifdamaged. welding area as traveling long, possibly cut off welding wire at compressed gas cylinders from excessive heat, slag, open flames, sparks, and arcs. Protect mechanical shocks, Install as a leather can gloves, heavy cap. Remove any combustibles, such as a butane from your person before doing any welding. FLYING METAL 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. cylinders in an upright position by securing to a stationary or cylinder rack to prevent falling or tipping. support Keep cylinders away from any welding or other electrical such lighter or matches, Injure eyes. Never drape Never allow Never weld a a welding welding on a torch over a gas pressurized cylinder - circuits. cylinder. electrode to touch any cylinder. explosion will result. Use only correct shielding gas cylinders, regulators, hoses, fittings designed for the specific application; maintain them associated parts in good condition. Turn face away from valve outlet when Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. 2 noise level is Shielding pipes, (see to AWS F4.1 pipes. protective garments shirt, cuffless trousers, high shoes, and Page can high. partition use. Wear oil-free OM-2227 equipment If electric shock and fire hazards. Remove stick electrode from holder contact or close to the current from welder to thaw frozen use or tanks, drums, they are properly prepared according Safety Standards). to processes the hidden side. unless practical some extinguisher nearby. ceiling, floor, bulkhead, on a damage hearing. damage hearing. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and spot and hot metal. Noise from Do not weld where or opening cylinder and and valve. Keep protective cap in place over valve except when cylinder is use or connected for Read and follow instructions associated Standards. in use. equipment, compressed gas cylinders, publication P-i listed in Safety on and CGA . 1-3 Symbols For Installation, Operation, And Maintenance Additional MOVING PARTS FIRE OR EXPLOSION hazard Do not install place or unit on, over, Do not install unit flammables. building wiring be sure power supply system properly sized, rated, and protected to handle this unit. Do not overload is near injury Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. or near combustible surfaces. A can cause - FALUNG UNIT can cause injury. HF. RADIATION lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacityto lift and interference. can cause Use High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications support unit. equipment. only qualified persons familiar with electronic equipment perform this installation. Have using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of If The unit. is user promptly for responsible having correct any interference a qualified electrician problem resulting from the installation. OVERUSE Allow cooling period; Reduce current starting Do not block or STATIC (ESD) Put or on follow rated reduce duty cycle. duty cycle grounded boards or by at once. FCC about interference, stop regularly using the 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. filter airflow to unit. can the If notified equipment Have the installation before again. to weld handling OVERHEATING can cause damage PC boards. wrist strap BEFORE parts. ARC WELDING static-proof bags and store, move, or ship PC boards. Use proper can cause interterence. boxes to Electromagnetic energy can interfere with electronic equipment such as computers and computer-driven equipment sensitive MOVING PARTS can cause such injury. Keep away from moving parts. Keep away from pinch points as robots. all equipment in the welding electromagnetically compatible. Be such as To reduce drive possible, rolls. sure WELDING WIRE can cause injury. possible interference, keep weld cables as short as together, and down low, such as on the floor. welding operation equipment. Be sure according Do not press gun trigger until instructed to do welding machine is and installed grounded to this manual. such Do not point gun toward any part of the body, people, or any metal when threading welding 1-4 this 100 meters from any sensitive elec If interference still occurs, the user must take extra measures as moving the welding machine, using shielded cables, using line filters, or shielding the work area. so. other is close Locate tronic area wire. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49. 1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superinten dent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, from Compressed Gas Association, Highway, Suite 501, Arlington, VA 22202. 1235 Jefferson Davis Safety in Welding and Cutting, CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3. Code for Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.i, from American Welding Society, 550 N.W. LeJeune Rd. Miami, FL 33126 Protection, ANSI Standard Z87.i,from American National Standards Institute, 1430 Broadway, New York, NY 10018. National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Cutting And Welding Processes, NFPA Standard 51 B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Practices For Occupation And Educational Eye And Face OM-2227 Page 3 EMF Information 1-5. Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields 1. Keep cables Welding current, as it flows through welding cables, will cause electro magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National 2. Arrange 3. Do not coil Research Council concluded that: The body of evidence, in the judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when 4. committees welding or magnetic procedures: OM-2227 Page 4 cables to or together by twisting one drape or taping side and away from the cables around your Keep welding power as practical. source Connect work to and cables them. operator. body. as far away from opera tor 5. clamp workpiece as close to the weld as possible. About Pacemakers: cutting. To reduce close fields in the workplace, use the following Pacemaker then wearers following consult your doctorfirst. If cleared by your doctor, procedures is recommended. the above SECTION 2 2-1. 1/96 - DEFINITIONS General Precautionary Label Warning! Watch possible hazards symbols. 1 Out! There are shown the as by Electric shock from welding electrode or wiring can kill. dry insulating gloves. 1.1 Wear Do not touch electrode with bare hand. Do not wear wet or damaged gloves. yourself from electric by insulating yourself work and ground. 1.2 Protect shock from 1.3 Disconnect input plug power before working or on machine. 2 fumes Breathing welding can be hazardous to your health. 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation exhaust to remove or local the fumes. 2.3 Use ventilating fan to fumes. remove 3 Welding sparks can explosion or fire. 3.1 Keep flammables away from welding. Do not weld near cause flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. 3.3 Do not weld drums on or any closed containers. 4 Arc rays can burn eyes and injure skin. 4.1 Wear hat and Use shirt safety glasses. protection and button collar. Use welding ear helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on 6 the machine or Do not remove or (cover) the label. welding. paint over OM-2227 Page 5 2-2. Input Connection Label Warning Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from kill. 2 . wiring can Disconnect 3 input plug working power before machine. 4 or on Read the Owners Manual before this working on machine. Consult 5 rating label for input power requirements, and check power available at the job site they must match. - Read Owners Manual and inside labels for connection 6 points Move 7 on 8 and procedures. jumper links as shown inside label to match voltage at Having a connect site. job loop of extra length, grounding conductor first. Connect line input conductors as shown on inside label double-check all connections, jumper link positions, and input voltage before applying 9 - power. Electric Sh ock And Airflow Label 2-3. 1 2 \ \ 1 3 \ Warning! Watch Out! There are possible hazards as shown by the symbols. \ \ \ \ 2 -e I e ~ I 3 0 Electric shock from and exposed can kill. wiring weld terminals Close door before turning on unit. S-179 563 1/96 2-4. Nameplate Safety Symbols 1 1 1 2 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from electrode 3 Sparks or wiring welding can kill. from can cause arcing electrode explosion or fire - disconnect cable for process not in use. 4 Read Owners connection 5 Manual for procedures. Electric shock from kill. wiring can 2 3 4 6 Disconnect input power working on unit or making terminal strip before connections. Nameplate OM-2227 Page 6 D-1 79 389 SECTION 3- INSTALLATION Amperes Input at Rated Load Hz, 50 Output, Three-Phase Voltage Range Welding Volts DC, 10 - 220 V Max OCV DC DC 40 45 Duty Cycle 35 34 31 23.3 17.6 1.6* 1.5* 1.4* 1.04* 0.37* Duty Cycle : : I: 500 ~ load without If percentage unit can of 1( weld at rated overheating. overheats, thermostat(s) opens, output stops, and cooli~ fan runs. Wait fifteen minutes unit to cool. Reduce amperage duty cycle before welding. 400 A o ~ 200 100 is minutes that unit ~ < ~oo ~ KW 61 600 ~ KVA 2.8* 900 800 700 LiJ 440 V 400 V 380 V Exceeding duty cycle damage unit and warranty. can ~ 30 20 10 40 50 60 70 8090100 % DUTY CYCLE 60% Duty Cycle g~-~g~ 6 Minutes 4 Minutes Welding Resting Overheating V 3-3. Volt-Ampere Curves Volt-ampere and 45 MAX of unit. Curves of 40 FC W show curves and maximum voltage amperage output capabilities minimum 50 between curves othersettingsfall shown. 35 30 ~ -J ~ 25 20 15 10 MIN 5 0 0 50 100 150 200 250 DC 300 350 400 450 500 AMPERES vacurvel - 4/95 - 197 034-A OM-2227 Page 7 Seb 3-4. A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye move Movement or lifting forks to unit. If using lifting forks, extend forks beyond opposite side of unit. Rating Label 3 Use rating label to determine input power needs. Label located under front access door. OR 4 Line Disconnect Device 2 Locate unit power supply. near correct input A Special installation may be required where gasoline or volatile liquids are present Location And Airflow - NEC Article 511 Section 20. see or CEC 18 in (460 mm) 18 in (460 mm) 3-5. Dimensions And Ref. 800 453-A Weights Dimensions D~h____ Height 27-1/4 in (692 mm) ___ 4 Holes I Width 22-1/4 in (565 mm) Depth 28-1/4 in (718 mm) A 27-1/2 in (699 mm) B 3/4in(lgmm) C 21 in (533 mm) D 1-3/16 in (30 mm) E 7/16 in (11 mm) Dia Weight 0 _____ - 1~~ Ref. 153 556-A OM-2227 Page 8 337 lb (153 kg) . 3-7. 115 VAC Receptacle And Circuit Breakers A Turn Off connecting power to before receptacle. 1 ll5Vl5AACReceptacle 2 Circuit Breaker CB1 3 Circuit Breaker CB2 RC9 CB1 115 volts protects receptacle RC9 from overload. CB2 DS-2 protects wire ac drive motor from overload. Press button to reset breaker. Ref. 800 452-B OM-2227 Page 9 Total Cable 100 ft Turn Off power before to weld output connecting terminals. = -ii jL + Positive Negative Ref. 800 452-B I 200ft 250ft (60 m) (70 m) I Exceeding I 300ft I 350ft (90 m) 400ft (105 m) (120 m) Duty Cycle Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0 (AWG) is based on either a 4 mm2 equivalent weld cable sizes. 3-9. 150 ft (45 m) In Weld Circuit Not Welding Amperes *WeId cable size for the (30 m) Or Less (Copper) Length 10 60% - volts or less 60 drop 100% - or a current 10 100% - Duty Cycle density of at least 300 circular mils per ampere. Contact your distributor S-0007-E Inductance Selection A Turn Off changing Remove power stabilizer before taps. cover. 1 Stabilizer Z 2 Lead 25 3 Stabilizer Z Center 4 Stabilizer Z 5 Lead 26 Tap Ending stabilizer Z is factory connected to the stabilizer end tap Tapped which is recommended for most gas-shielded flux use with cored wires. Stabilizer Z controls the induc applied to the weld current. To decrease inductance for recom mended with most selfuse tance shielded flux cored wires, discon nect lead 26 from stabilizer end tap and connect to stabilizer tap as center shown. Reinstall cover. Tools Needed: ~ 3/8,7/l6in ~Zl~1J 3/8 in 802 623 OM-2227 Page 10 . 3-10. Remote 9 pin Receptacle RC8 Information Socket Information Socket REMOTE 9 24 volts ac output for gas valve control when triggered or purging when gas. 010 trigger open, 2 +15 volts dc with gun 3 Circuit 4 0 to +10 volts dc 5 +10 volts dc 6 0 to +10 volts dc input 7 +15 volts dc with Jog 8 0 to +24 volts dc output 9 Voltage output 0 volts dc with gun trigger closed. common. input Output Command from mm to max of from mm to max of Wire control Ri. FEEDER output. Speed control R2. switch S3 open, 0 volts dc with switch closed. to motor Mi with respect to wire drive motor Mi with to socket 9. respect to socket 8. 3-11. Electrical Service Guide 220 380 400 440 61 35 34 31 2 70 40 40 35 3 90 50 50 45 6 8 8 8 (99) (120) 10 10 Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Time-Delay Normal Mm Input Conductor Max Recommended Mm Size In AWG/KcmiI Input Conductor Length Grounding Conductor Size 2 factory for circuit breaker ?~1) (Meters) 10 8 (NEC) applications. Time-Delay fuses are UL class RK5. Operating (general purpose 3 Normal In Feet In AWG/Kcmil Reference: 1999 National Electrical Code 1 Consult Operating 1 - no intentional delay) fuses are (JL class K5 (up to and including 60 amp), and UL class H (65 amp and above). OM-2227 Page 11 3-12. Placing Jumper Links And Connecting Input Power Check input voltage available at site. 2 1 Jumper Link Label Check label. 220V C L~L2 LTS ~ 380 VOLTS ofit~o oflflo ~ - 0 ~L3 ~J,J . ~L3 foo oo 400 OLTS c~, Co ~ a ~ jL~ 2 IIcLYQI..TS ~ a L3 C L..~j 0O~0 ~i a,> aft~a ~ Link jumper links to match input voltage, and label on unit. 3 L Jumper Move Input And Grounding Conductors See Section 3-11. 1 4 Line Disconnect Device See Section 3-11. Close access door. Li L2 L3 A Always connect grounding conductor = first. 3 GND/PE EI~1~~j~u 3/8, 1/2 in 801 382 OM-2227 Page 12 SECTION 4- OPERATION 4-1. Welding Power Source Controls 196 996-A 1 Analog Meters Voltmeter and ammeter voltage 2 to purge gas display actual and amperage with contactor adjust gas regulator. pendant. At second trigger closure, welding arc extinguishes. Crater Fill On Crater At initial gun trigger closure and release, unit creates and sustains a welding arc using This Crater Fill Wire Speed Control (Used With Crater Fill Mode Only) Crater Fill Voltage Adjustment Control (Used With Crater Fill Mode Only) welding. settings from weld controls on wire feeder pendant. At second trigger closure, weld parameters change to settings from crater fill controls on welding power source. At second trigger release, welding arc extinguishes. momentarily energize gas valve Fill/Trigger Hold Off setting is normal operation. At gun trigger unit initiates welding arc using settings from weld controls on wire feeder pendant. At trigger release, welding arc extinguishes. closure, A Turn Off power before connecting remote device. Trigger Hold On 6 Purge Switch Use switch to to output Turn control clockwise to increase crater fill voltage. Control can be adjusted while 4 or on. Scale is calibrated in meters per minute. 3 lines, Mode Switch 5 At initial gun trigger closure and release, unit creates and sustains a welding arc using settings from weld controls on wire feeder High Temp Shutdown Light Light turns on condition that to indicate causes output an overheated to shutdown. OM-2227 Page 13 4-2. Pendant Controls Controls pendant mounted. An pendant extension are remote optional cord is available. 1 . Nameplates has Pendant nameplates on top of the other. nameplate contains the vol stacked Each three one tage and amperage ranges for a dif ferent size flux cored welding wire (for reference only). Unit is shipped mm wire nameplate on top. change to 1.4 or 1.6 mm name plates, see Wire feeder owners with 1.2 To manual. 2 Voltage Control Use control to set source voltage Numbers 3 Wire Use for reference are power only. Speed Control control speed welding at the wire feeder. to from adjust 0 to 20 wire meters feed per minute. 111) l~ Match colored bands on voltage and wire speed cont rols to get an acceptable welding 4 condition. 4 Jog Switch Jog switch to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas Use valve. Use And Nameplates As A Voltage Amperage Reference Only. Ret. 802 483-A / 199 3431199 348 /199 350 OM-2227 Page 14 SECTION 5- MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance A Disconnect power before maintaining. __ 3 Months Replace unreadable labels. 6 Months Blow out or vacuum -~ inside. During heavy service, monthly clean Or Trouble No weld output; inoperative. unit Remedy Place line disconnect switch in On completely Check and replace Check for proper line fuse(s), No weld light output; Power switch pilot Check, repair, or replace if necessary, connections input power Check for proper jumper link position (see Section 3-12). or (see Section (see Section 3-12). 3-12). position (see Section 3-12). feeder (see wire feeder Owners Manual). on. Unit overheated. Allow unit to cool with fan On Unit reset circuit breaker provides only maximum output. or minimum weld Erratic or improper weld Authorized Service Agent check control board PCi and/or motor drive board PC2. Have Factory Authorized Service Agent check control board PCi, motor drive board PC2 and Hall Device HD1. Use proper size and output. tighten Use proper type of weld cable tap on stabilizer according duplex re- Reset circuit breaker CB1 to Owners Manual. (see Section 3-9) Factory Authorized Service SCR in main rectifier. at (see Section 3-8). all weld connections. Have output 3-2). Factory Check wire feeder installation ac Section Have Clean and No 115 volts (see Agent check control board PCi, motor drive board PC2 and/or (see Section 3-7). ceptacle. Fan not when operating. Note: fan cooling is necessary. runs only Check for and Have Factory remove anything blocking Authorized Service Agent fan movement. check fan motor. OM-2227 Page 15 Remedy Trouble Wire does not feed, feeder completely Check 9-pin plug PLG8 Check input connections (see Section 3-10). inoperative. . power. Check circuit breaker CB2 Wire does not feed. on Check gun trigger connection at wire feeder and trigger switch. Have Wire feeds erratically. Service Factory Authorized Readjust or replace dirty Remove weld Replace Have Wire feeds when but not when gun Wire feeds Wire does pressed, trigger is as soon as not or power is feed until trigger is check drive motor, control board or worn wire feeder owners drive roll (see tip or Check PCi, and trigger leads motor board PC2. manual). manual). wire feeder owners manual). liner. Authorized Service Agent check drive motor and control board PCi. Check gun trigger connection at wire feeder and trigger switch. Check gun wire feeder owners Check gun spatter around nozzle opening. contact Factory (see (see (see Section 3-7). (see wire feeder owners manual). Check gun trigger leads trigger. position Crater Fill On of Mode switch or Trigger welding power source. This positions (see Section 4-1). is normal on Hold On operation when switch is in released. loudly erratically. and wire feeds Gas does not flow; wire feeds. OM-2227 applied. but continues to feed after Gas valve rattles slowly Jog switch is pressed trigger is pressed. Agent (see wire feeder owners manual). hub tension and drive roll pressure Use correct size drive roll Clean source, and reset if necessary welding power Page 16 Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads. Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads. Check gas valve and flowmeter. SECTION 6- ELECTRICAL DIAGRAM I I? I ~Jo ~ ~3-)F~3-) ~-)4 ~>--(~ ;--~~~-- j~t; ~ m 000000 :fl~:f!:~f~ r~i ~ 11 ~AAA RCI-8>> ~(RC36 I I ~ -~ I RC1-5>> <RC35 I, ~(Rcs13 - ~1 ~ __________________________________ - _______ Sc, RCl-4>> I RC1 -3>> ~ RCI 2 ______I ~Fc, ~ ~:J - UT~ ~ ~ Rd-I RC3-12 RCI-7)> RC1-8>> <<RC3-l1 -~-1 1-~~ ~ i~\1 RC1-R>> RCI-1O>>- 24 VAC GAS VALVE > ~NTAC1OR ~.9 RC31O>>~RdS8>>~- aPOJIr ~MMON ~<RC3-7 ~ RC3-2>>- OUTPUT COMMRNO >~+1O VOC REFU~1~E ~_)C~~ ~j~<4-~ (cOMMAND & RC3-18>>~ ~) ~ ~x,._____!~ki ~)>~J ~.T~< ~ ~ WFS) ~ ~ r V ______ ________ i~ AAAA -~r7 A ~ ~ ~ 9<RCII12 $<RCII-IO A RCI 1-16 <RCII-9 RCII-4> ~ L ~ RC1O-3>~ JOG <601-13 ~<RCIO-6 ~~~~_uOTOR POWER Rd1UW9 <RdlO6 ~rr?I~ -o 0 (I, -, P1 197 032-C Figure 6-1. Circuit Diagram OM-223 Page 17 SECTION 7- PARTS LIST Hardware is common and not available unless listed. Figure OM-2227 Page 18 7-1. Main Assembly ST-802 606 Item No. Dia. Part No. Mkgs. Description Figure 7-1. Main Quantity Assembly 2 4 197028 179429 Panel, Side Label, General Precautionary Wordless, Intl Baffle, Air Cover, Top 5 177279 Gasket, Lift Eye 1 6 162830 7 162820 1 +179430 2 176254 3 8 C16 048504 9 087111 10 173605 11 HD1 168829 Figure 12 TEl 7-2 038138 038 618 175 479 .14 15... 032 765 C21-23.... 137 771 Zi 196 995 162 816 163 533 2 1 1 2 1 1.39 Dia 1 1 Transducer, Current 1 000a Module Max Open Loop 1 Panel, Rear Term Assy, Pri 1 3ph 3v 1 (Consisting Of) Jumper, Link Jumper, Link 220V Bracket, Support Leads Capacitor 3 6 2 Diode 3 Stabilizer 1 Channel, Upright 4 1 ....Base 1 TP1-2 175 405 TP4-5 168 891 Xfmr, Power Main 380/400/440 (consisting of) Coil, Pri/Sec 380/400/440 Coil #1 Coil, Pri/Sec 380/400/440 Coil #2, #3 Thermostat, Nc Open/Close 135C (Included w/T1) Thermostat, Nc Open 80C Close SOC (Included w/T1) PLG13. PLG6 189 873 Connector & Pins 1 168 847 Connector & Sockets Connector & Pins Panel, Front 1 Bracket, Mtg Rectifier Rectifier, Si Diode 2 152249 Connector & Pins 1 168846 Connector & Sockets Connector & Pins 1 Ti 197 152 .20... 197 303 .21... 197 304 RC6 168845 Figure 7-3 161 294 .23... ...24... ....LiftEye Bar, Mtg Lift Eye Capacitor, Elctlt 5000 Ut 50 Vdc Can Clamp, Capacitor 1.375 Dia Clip Bracket, Mtg Lem 2 SRi ... PLG7 Figure .... RC7 .PLG14.... +When ordering *Recommended a 7-4 115094 component originally displaying Spare a 1 2 2 2 1 1 1 1 precautionary label, the label should also be ordered. Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-2227 Page 19 Item No. Dia. Part No. Mkgs. Description Figure 173 283 180 165 162 807 168 343 .. .. . 8 .. . 9 .. .10 +162 818 .. 179290 .. 010467 124274 Hardware is R5 114808 FM 116190 common 7-2. Quantity Panel, Rear w/Components (Figure 7-1 Item 12) Chamber, Plenum 14 In Blade, Fan 14.000 3wg 28deg .375 Bore Ccw Gal Panel, Rear 1 Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h Door, Access Primary Label, Warning Electric Shock Input Connection Ce Conn, Clamp Cable 1.250 Bracket, Mtg Fan Motor 2 1 1 1 W 1 1 1 Resistor, Ww Fxd 375 W 5 Ohm W/Hardwa Motor, 1/l2hp 230v 1550 Rpm 50/60hz 1 .5a and 3 1 1 4 not available unless listed. 6 8 ST-802 608 Figure +When ordering a To maintain the Replacement OM-2227 Page 20 7-2. Panel, Rear wlComponents component originally displaying a precautionary label, the label should also be ordered. factory original performance of your equipment, use only Manufacturers Suggested Parts. Model and serial number required when ordering parts from your local distributor. l~ Hardware is common and 3 not available unless listed. 4 8 7 9 I0 .11 2 9 5 26 16 ST-802 607 Figure Item No. Dia. 7-3. Part No. Mkgs. Description Figure 197 733 PCi 196 994 PLG3.... 169 240 PLG5.... 152 249 CB1 093 995 Receptacle/Capacitor w/Leads (Consisting Of) Connector & Sockets 1 Connector, Circ Skt Push-In 14-18 Ga 7 Assy, Elect Assy, Elect Assy, Elect 1 Panel, Front Terminal, Pwr Output Red 1 Capacitor, Cer Disc .1 Ut 500 Vdc W~Terms Light, md Wht Lens i25vac Snap-in Neon Non-relampa Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl Spring, Cprsn .600 Od X .072 Wire X 1.500 PId Terminal, Pwr Output Black 2 C3 197 751 Lead 197 753 C15 197 755 Lead Lead 181 245 128 750 PL1 163 562 Si 128 756 161 303 181 246 14 172587 15 +179 563 16 160935 SN1 CR1 197868 052964 PC2 196998 ....PLG1O.... 168071 PLG11 169240 PL2 1 1 1 1 3 1 Cover, Output Stud Generic Label, Electric Shock/Reduce Air Flow (Ce) 1 Clip, Spring Snubber, Assy Relay, End 24Vdc Dpdt 1OA/l2OVac Circuit Card Assy, Motor Drive 3 1 1 8Pm 1 Flange Mtg 1 1 Stand-off 4 196996 Nameplate, Miller Deltaship 1 159522 Led, Yellow 2.1V 2OMa 45.0 Mcd Panel Mtg .250 Hole 1 192174 21 1 Connector & Sockets Connector & Sockets .... 20 1 079 534 C6 NEG 1 199 894 11 22 1 197 748 10 19 1 1 1 604 176 12 22) 1 RC9 ..PoS C4-5 7-1 Item Electronics Box Circuit Card Assy, Control Connector & Sockets 161 078 196 992 18 Panel, Front w/Components (Figure CB2 RC8 17 7-3. Quantity Connector & Sockets Circuit Breaker, Man Reset 1 P 1 5A 250 Vac Circuit Breaker, Man Reset 1 P 7A 250 Vac Rcpt, Str Dx Grd 2P3W iSA 125V *515R ...6 13 Panel, Front w/Components 1 OM-2227 Page 21 Owners Please complete Record and retain with your Number Serial/Style Model Name Purchase Date (Date which equipment was personal records. delivered to original customer.) Distributor Address City Zip State Resources Available Always provide Model Name and Contact your Distributor for: a distributor or service agency you, call 1-800-4-A-Miller or visit our website at www.MillerWelds.com To locate Serial/Style Welding Supplies Options Number. and Consumables and Accessories near Personal Safety Equipment Service and Repair Replacement Mitler Etectiic company ~635 West Spencer Street: App~toa,WI54914USA Training (Schools, Videos, Books) International Technical Manuals and Parts) Mfg CO~ An illinois Tool ~rks Parts (Servicing Information Headquarters-liSA USA Ptione~ 920-735-4505 Auto-Attended USA & Canada.FAX 920-7354134 .: tmationai FAX 920-735-4125 Circuit Diagrams Welding ~uropeanHeadquarteis :Unftad Process Handbooks www Delivering Carrier for: File a claim for loss or MdlerWekls corn .~ damage during shipment. For assistance in filing or settling claims, equipment Department. contact your distributor and/or manufacturer s Transportation _ ~I/i Miller W PRINTED IN USA ' 2000 Miller Electric . .. 44(0)1204-593493 44 (0)1204598066 Phone: FAX Contact the - Kingdom Mtg. Co. 1/00 Th~erifBhte.