Miller | LJ490115V | Owner Manual | Miller HDC 1500DX CE User manual

Miller HDC 1500DX CE User manual
OM-212 296Q
2008−11
Processes
Submerged (SAW) Welding
Description
Submerged Arc Controller For
Automatic Welding
HDC 1500DX
CE
50, 60 Hz
Visit our website at
www.MillerWelds.com
File: SUBMERGED (SAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Typical Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Typical Connection Diagram With Miller Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Left Side Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Terminal Block TB1 And TB2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Terminal Block TB1 Connection Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Terminal Block TB2 Connection Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connection Of 115 VAC Flux Hopper Without Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Remote 10 Receptacle RC2 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Remote 4 Receptacle RC3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Remote Voltage Sense Leads Placement Guidelines For A Single Arc (Required) . . . . . . . . . . . . . . .
5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Power Source Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Power Switch And Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Program Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Flux Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MOTOR TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SETTING SEQUENCE PARAMTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
9
9
10
10
10
11
11
11
12
12
12
13
14
15
16
16
17
18
18
19
20
21
23
24
24
24
24
25
25
26
26
27
27
27
28
29
30
30
TABLE OF CONTENTS
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
34
35
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:
Product
Stock Number
HDC 1500 DX
300438
Council Directives:
S
2006/95/EC Low Voltage
S
2004/108/EC Electromagnetic Compatibility
S
2006/42/EEC Machinery Directive
Standards:
S
IEC 60974-1 Arc Welding Equipment - Welding Power Sources: edition 3, 2005-07.
S
IEC 60974-5 Arc Welding Equipment – Wire Feeders: edition 1.1, 2002-02.
S
IEC 60974-10 Arc Welding Equipment - Electromagnetic Compatibility Requirements: edition 1.1,
2004-10.
US Signatory:
November 25, 2008
__________________________________________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
241813A
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D 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.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-212 296 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes 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 Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
MAGNETIC FIELDS 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.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
Noise from some processes or equipment can
damage hearing.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
OM-212 296 Page 2
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
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 UNIT can cause injury.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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.
FLYING SPARKS can cause injury.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-212 296 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (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,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, 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 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
2. Arrange cables to one side and away from the operator.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-212 296 Page 4
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About 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_2007−04
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
D
D
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
D
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
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 afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D Ne pas toucher aux pièces électriques sous tension.
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 Porter des gants isolants et des vêtements de protection secs et
sans trous.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
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 toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
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
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.
OM-212 296 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a
coupé l’alimentation.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
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 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 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 En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
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 pro
voquer des brûlures dans les yeux e
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-212 296 Page 6
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D 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 Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
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.
LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.
D Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
D 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.
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.
LE BRUIT peut endommager l’ouïe.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de soudage, les manipuler avec précaution.
D 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’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
LES ÉTINCELLES VOLANTES risquent de 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.
SUR-
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
OM-212 296 Page 7
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
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.
DES ORGANES MOBILES peuvent
provoquer 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 Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
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.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
D
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D
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
D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
OM-212 296 Page 8
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : 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, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
2-6. Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les 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.
OM-212 296 Page 9
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
Hz
Hertz
I2
Rated Welding
Current
A
Amperes
Remote
V
Volts
Input
Percent
Circuit Breaker
Increase/Decrease
Of Quantity
Wire Feed Speed
Protective Earth
(Ground)
Postflow Timer
Preflux Timer
Start Time
Start
Stop
X
Output
Single Phase
Alternating
Current
Primary Voltage
IP
Degree Of
Protection
Rated Supply
Current
Line Connection
U2
Conventional Load
Voltage
On
Off
Wire Feed Inch
Down
Crater Time
Program
Flux
Duty Cycle
I1
U1
Wire Feed In Up
3-2. WEEE Label (For Products Sold Within The EU)
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.
OM-212 296 Page 10
SECTION 4 − SPECIFICATIONS
4-1. Weld Control
Specification
Description
Type Of Input Power From Welding
Power Source
Single-Phase 115 Volts AC, 10 Amperes, 50/60 Hertz
Welding Power Source Type
Constant Voltage (CV), AC Or DC
Welding Processes
Submerged Arc (SAW) Welding
Overall Dimensions Including Knobs,
Receptacles, Etc.
Weld Control — Height: 11.5 in (292 mm); Width: 12.5 in (318 mm); Depth: 7 in (178 mm)
Weight
Weld Control — Net: 25.5 lb (11.6 kg)
Weld Voltage And Amperage
Capacity (AC Or DC)
0 To 100 Volts
0 To 1500 Amperes
4-2. Description
This weld control is designed to automatically cycle welding events.
This unit can be used with constant
voltage, AC or DC welding power
sources. Relay contacts that work
in conjunction with the weld cycle
are available to interface with other
equipment (such as fixtures and
flux valves). See Section 5-5 and
5-7 for connection information on
TB2.
For information on the wire drive assembly, see Owner’s Manual supplied with the assembly.
803 448-A
OM-212 296 Page 11
SECTION 5 − INSTALLATION
5-1. Typical Equipment Location
1
2
3
4
5
6
Welding Power Source
Side Beam
Weld Control
Spool Support
Wire Drive Assembly
Automatic Welding Gun
4
3
5
2
1
6
Ref. 131 138-A
5-2. Mounting Hole Layout
8 in
(203 mm)
5/16 in
(7.9 mm)
Dia. 4 Holes
10-3/4 in
(273 mm)
7 in
(178 mm)*
* Includes front panel knobs
Ref. 803 021-B
OM-212 296 Page 12
5-3. Typical Connection Diagram With Miller Power Sources
. Customer must supply the following: power source, power source control cable, wire drive assembly, wire drive assembly cable, drive rolls, gun,
welding wire, weld cables, remote voltage sense leads and flux system for the desired application.
!
Turn Off welding power
source and weld control
and disconnect input
power before making
connections.
. Use remote voltage sense
leads in all applications.
. Suggested
size remote
voltage sense wire is 12
gauge or higher.
. See power source owners
manual for sense lead terminal strip location and
connection.
. For DCEN (straight polarity) observe sense
lead relationship with power source output
polarity. Example - N to (−) or work output stud
and P to (+) or electrode output stud.
4-Pin Flux
Valve Cord
FLUX
SYSTEM
14-Pin Welding
Power Source
Control Cord
HDC
1500DX
FLUX
VALUE
WELDING
POWER
SOURCE
10-Pin Motor
Control Cord
WIRE
DRIVE
ASSEMBLY
(+) Electrode Stud
N
P
(−) Work Stud
WORKPIECE
Welding Cables
Remote Voltage
Sense Leads
DCEP (Reverse Polarity) Connection
OM-212 296 Page 13
5-4. Left Side Panel Connections
1
2
A
C
D
J
K
B
L
I
N
H
M
E
1
2
3
Receptacle
Keyway
Access Hole - For Customer
Use: Connections To Terminal
Blocks, Flux Valve, etc.
!
Turn Off welding power
source and weld control and
disconnect input power before opening access door.
3
G
. Install strain relief (customer
F
supplied) in access hole.
4
Example Receptacle
RC3
Route incoming cables through
user access hole prior to making
connections to internal terminal
blocks.
4
RC1
5
5
6
RC2
6
4-Pin Receptacle:
Connection To Flux
Hopper/Shielding Gas Valve.
14-Pin Receptacle:
Connection To Welding Power
Source.
10-Pin Receptacle:
Connection to Wire Drive
Motor
To connect matching interconnecting cord to one of the above
receptacles, align keyway, insert
plug, and tighten threaded collar.
Connect remaining end of cord to
matching receptacle on applicable
equipment.
Ref. 803 449-B
OM-212 296 Page 14
5-5. Terminal Block TB1 And TB2 Connections
!
Turn Off welding power
source and weld control and
disconnect input power before opening access door.
1
Access Door
Remove securing screw and open
access door.
2
3
4
5
6
7
7
Terminal Block TB2
Terminal Block TB1
Securing Screw - Terminal
Block
Stripped Lead
Typical Lead Being
Connected To Terminal Block
Access Hole - Used For
Connections To Terminal
Blocks, Flux Valve, etc.
. Install strain relief (customer
supplied) in access hole.
Strip 1/4 in (6 mm) insulation off end
of lead, insert end into proper location on TB1 and TB2. Tighten applicable securing screw.
Close and secure access door.
1
Tools Needed:
2
3
4
1/4 in
(6 mm)
5
6
Ref. 803 450-B
OM-212 296 Page 15
5-6. Terminal Block TB1 Connection Information
Terminal/Number
Receptacle Location
Function Information
A
A on 14-Pin
B
B on 14-Pin
A normally open set of relay contacts connect terminal A to terminal B when
Start is pressed and pre-flux timer times out (contacts are rated 10 amperes, 125
volts AC).
C
C on 14-PIn
Remote command reference from welding power source.
D
D on 14-Pin
Remote circuit common.
E
E on 14-PIn
Output command to welding power source (0 to 10 volts DC).
G
G on 14-PIn
Circuit common for 24 and 115 volts AC circuits.
I
I on 14-PIn
115 volts AC from welding power source, which is present whenever welding
power source is on.
F
F on 14-PIn
Current feedback input (1 volt DC per 100 amperes).
H
H on 14-PIn
Voltage feedback input (1 volt DC per 10 arc volts).
K
K on 14-PIn
Chassis common.
Remote Stop
When connected to remote common, stops the weld cycle.
Remote Jog Down
When connected to remote common, jogs wire down.
Remote Common
Circuit common for remote capabilities.
5-7. Terminal Block TB2 Connection Information
Terminals
Red
Function Information
115 volts AC to power flux hopper.
Black
Switched 115 volts AC to power flux hopper.
White
Circuit common for 115 volts AC for flux hopper.
Green
Chassis common for flux hopper.
Side Beam 1 Relay
Normally open set of contacts* that close when the Start button is pressed or after a set time after the arc has
been established (see Section 6-11). Contacts open again when the Stop button is pressed.
Side Beam 2 Relay
Normally open set of contacts* that close when an arc is established. These contacts are used when you want
the side beam to start moving once an arc has been established. Contacts open again when the Stop button is
pressed.
Remote Start
Remote Jog Up
Remote Program
When connected to remote common, starts the weld cycle.
When connected to remote common, jogs wire up.
When connected to remote common, increments the program.
* NOTE: All contacts are rated 10 amperes, 125 volts AC.
OM-212 296 Page 16
5-8. Connection Of 115 VAC Flux Hopper Without Plug
Four-Conductor Cable
From Flux System
!
Turn Off welding power
source and weld control and
disconnect input power before opening access door.
1
Access Door
Remove securing screw and open
access door.
2
3
Terminal Block TB2
Access Hole - Used For
Connections To Terminal
Blocks, Flux Valve, etc.
. Install strain relief (customer
3
supplied) in access hole.
Strip 1/4 in (6 mm) insulation off end
of leads. Insert four-conductor
cables from flux system through access hole, and make connections
as shown.
Close and secure access door.
Tools Needed:
1
2
Four-Conductor Cable
From Flux System
Black Lead
Red Lead
Green Lead
White Lead
Ref. 803 629-A
OM-212 296 Page 17
5-9. Remote 10 Receptacle RC2 Information
Socket
REMOTE 10
Wirefeed Drive
Motor Hookups
Socket Information
A
To positive (+) motor armature (115 volts DC motor).
B
To negative (−) motor armature (115 volts DC motor).
C
To motor field.
D
To motor field.
E
Chassis common.
F
Tachometer feedback; 0 to +12 volts DC.
G
12 volts DC to power tachometer
H
Circuit common for +12 volts DC circuit.
I
Not used.
J
Not used.
10 Pin Motor Cable
Ref. 212 591-A
5-10. Remote 14 Receptacle RC1 Information
Socket
User Accessible
Via TB1
Socket Information
Terminal #
A
A
24 volts AC or 115 volts AC from welding power source (present
whenever power source is On).
B
B
Normally open set of relay contacts connect A to B when Start is
pressed and preflux timer has timed out.
C
C
Remote command reference from power source; +10 volts DC.
D
D
Remote circuit common.
E
E
Output command signal to power source; 0 to +10 volts DC.
F
F
Current feedback input from power source; +1 volt DC per 100 amperes.
H
H
Voltage feedback input from power source; +1 volt DC per 10 arc
volts.
G
G
Circuit common for 24 and 115 volts AC circuits.
I
I
115 volts AC from welding power source (present whenever welding
power source is on). 115 volts AC is present on terminal block TB1
whenever welding power source is on.
K
K
Chassis common.
Contactor Control
Remote Output Control
Amperage/Voltage Feedback
Electrical Input Power
GND
14 Pin Interconnecting Cable
Ref. 178 836
OM-212 296 Page 18
5-11. Remote 4 Receptacle RC3 Information
Socket
User Accessible
Via TB2
Socket Information
Terminal #
Flux Hopper Hookups
A
Red
115 volts AC to power flux hopper.
B
Black
Switched 115 volts AC to power flux hopper.
C
White
Circuit common for 115 volts AC for flux hopper.
D
Green
Chassis common for flux hopper.
4 Pin Flux Hopper Cable
Ref. 300 484-A
Notes
OM-212 296 Page 19
5-12. Remote Voltage Sense Leads Placement Guidelines For A Single Arc (Required)
Remote Voltage
Sense Leads
WELDING
POWER
SOURCE
BAD
Sense lead is affected by weld
current.
Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.
Work
Clamp
. Refer to power source owner’s manual for
sense lead connection to terminal strip.
Remote Voltage
Sense Leads
WELDING
POWER
SOURCE
BEST
Sense leads are out of the current
paths.
Sense leads detect arc voltage accurately.
Best starts, arcs and most reliable
results.
Work
Clamp
Ref. 804 108-A
OM-212 296 Page 20
5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs
Lead
WELDING
POWER
SOURCE
BAD
Current flow from lead affects trail
sense.
Current flow from trail affects lead
sense.
Neither sense lead picks up the
correct work voltage, causing
starting and welding arc instability.
Trail
Remote Voltage
Sense Leads
WELDING
POWER
SOURCE
Lead
Trail
Work
Clamp
Trail
Lead
. Refer to power source owner’s manual for
sense lead connection to terminal strip.
Lead
WELDING
POWER
SOURCE
BETTER
Lead sense is only affected by
weld current from lead.
Trail sense lead is only affected
by weld current from trail.
Trail
Remote Voltage
Sense Leads
Trail
Lead
Due to voltage drops across work
piece, arc voltage may be low,
causing need for deviation from
standard procedures.
WELDING
POWER
SOURCE
Work
Clamp
Work
Clamp
Trail
Lead
Ref. 804 108-A
OM-212 296 Page 21
5-13. Remote Voltage Sense Leads Placement Guidelines For Multiple Arcs (Continued)
Lead
. Refer to power source owner’s manual for
sense lead connection to terminal strip.
WELDING
POWER
SOURCE
BEST
Both sense leads are out of the
current paths.
Both sense leads detect arc voltage accurately.
No voltage drop between lead and
trail sense.
Trail
Remote Voltage
Sense Leads
Best starts, arcs and most reliable
results.
WELDING
POWER
SOURCE
Lead
Trail
Work
Clamp
Trail
Lead
Ref. 804 108-A
OM-212 296 Page 22
5-14. Power Source Selection Menu
1
2
Upper Display
Lower Display
. When the controller is turned
1
on, the Power Source Selection Menu allows the operator
to select a power source.
First Time Controller Is Turned
On
2
Power Source
Upper Display
Summit Arc 1000
SUM
1000
Summit Arc 1250
SUM
1250
Dimension 652 Sub Arc
DIM
652
Dimension 812 Sub Arc
DIM
812
Dimension 1000
DIM
1000
Dimension 1250
DIM
1250
Sub Arc DC 650
DC
650
Sub Arc DC 800
DC
800
Sub Arc DC 1000
DC
1000
Sub Arc DC 1250
DC
1250
Lower Display
The controller automatically goes
into the Power Source Selection
Menu. The controller displays
“DIM” on the Upper Display and
“1000” on the Lower Display, meaning that a Dimension 1000 is the selected power source.
At power up, the operator has five
seconds to select a power source
from the list shown on the display.
Operator may scroll through the list
of power sources by using the Adjust control. After selecting a power
source the operator has five seconds to change to a different power
source or begin welding. After making a power source selection, the
operator may press the Program
Button to avoid having to wait the
five seconds. When turning off the
controller, the selected power
source will be retained.
Next Time Controller Is Turned
On
The controller will display the last
selected power source. The operator has five seconds to select
another power source, or press the
Program Button to exit the Power
Source Selection Menu.
Disabling The Power Source
Selection Menu
Once the power source has been
selected the Power Source Selection Menu may be disabled using
the Auxiliary Menus. See Section
6-11.
236 564-B
OM-212 296 Page 23
SECTION 6 − OPERATION
The following is a list of terms and their definitions as they apply to this product.
General Terms:
Sequence
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
Weld Program
A group of sequences that make up a weld cycle.
6-1. Safety Equipment
Wear the following while welding:
1
3
2
1
2
3
Dry, Insulating Gloves
Safety Glasses With Side
Shields
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
6-2. Power Switch And Buttons
1
2
3
4
5
Power Switch
Start Button
Stop Button
Inch Up Button
Inch Down Button
2
3
1
5
4
803 448-A
6-3. Program Push Buttons
1
Program Display
The number of the active program
is displayed.
2
1
3
2
Program Push Button
Press button to activate program
selected feature. To change the
program number, press the Program push button, or rotate the Adjust control.
3
Program Push Button LED
The LED lights to indicate the Program push button is active.
Ref. 236 564-B
OM-212 296 Page 24
6-4. Front Panel Controls
See
Section 6-3
See
Section 6-5
See
Section 6-6
See
Section 6-10
See
Section 6-9
See
Section 6-7
See Section 6-8
Ref. 236 564-B
6-5. Upper Display
3
1
2
4
V
t (sec)
5
1
Upper Display
The upper display shows voltage or time. The
unit displays both preset and actual arc voltage. When the unit is in a welding state, actual arc voltage is displayed. The upper display
shows welding sequence time when the Time
LED is illuminated.
2
Upper Display Push Button
Press and hold button to adjust or display
weld time. Release button to display voltage.
3
Upper Display Push Button LED
The upper display push button LED illuminates to indicate that information displayed
can be changed with the Adjust control.
4
Volts LED
5
Time LED
The LED’s below the display illuminate to indicate which value is being shown.
At any time while welding, the unit permits the
adjustment of the weld sequence voltage.
• If the unit is displaying a welding sequence
that can be timed, the welding time display
mode is entered by pressing the upper display push button repeatedly until welding
time is the active parameter in the upper
display. At idle, the upper display toggles
between showing weld voltage or weld time
with subsequence presses of the upper
display push button.
• The unit defaults to displaying welding voltage when a welding sequence display
mode is first entered.
OM-212 296 Page 25
6-6. Lower Display
3
1
2
4
A
5
1
Lower Display
The lower display shows wire speed or amperage.
2
Lower Display Push Button
Press button to choose between wire speed
or amperage functions.
3 Lower Display Push Button LED
The lower display push button LED illuminates to indicate that information displayed
can be changed with the Adjust control.
4 Wire Speed LED
5 Amps LED
The LED’s below the display illuminate to indicate which value is being shown.
• At any time during welding, the weld sequence wire speed can be adjusted and
overrides the preset wire speed display. In
other words, if the Adjust control is activated while welding, the unit displays and
permits adjustment of the weld sequence
wire feed speed regardless of the active
welding sequence.
6-7. Setup Push Button
1
1
Setup Push Button
2
Setup Push Button LED
JOG
The jog speed selection, indicated by “JOG”
in the upper display, can be changed by turning the Adjust control. The jog wire feed speed
setting is the same for all programs. The jog
wire feed speed may also be adjusted while
the INCH UP or INCH DOWN buttons are
pressed.
MODE
Welding mode indicated by “MODE” in the upper display is set to “CV” for constant voltage,
or “CV+C” for constant voltage plus current.
This setting is program specific.
Run-In
The run-in wire speed selection, indicated by
“RUNI” in the upper display, is set to automatic , off, or manual run-in wire speed. The lower
display shows “AUTO” to indicate that auto-
OM-212 296 Page 26
2
matic run-in is active. The Adjust control can
be used to change the setting from “AUTO”,
to a run-in wire speed setting. If a start condition is set, run-in is a percentage of the start
wire speed, otherwise run-in is a percentage
of the weld wire speed. The active program is
displayed in the Program display. The active
program can be changed by pressing the Program push button, and then selecting the desired program with the Adjust control.
Run-in settings are program specific. For example, program 1 can be set to 40% run-in,
and program 2 can remain on the Automatic
setting.
BURNBACK
Burnback time and voltage are specified
when the display indicates “BURN” in the lower display, and voltage and time in the upper
display. The Adjust control is used to set the
desired burnback time or voltage.
Burnback retract wirespeed is specified when
the display indicates “BURN” in the upper dis-
play. Burnback retract wirespeed may be
turned to “OFF” with the lower display push
button or changed with the Adjust control.
Flux Valve Control
Flux valve control, indicated by “FLUX” in the
upper display, is set to “AUTO” for automatic
control, or “MAN” for manual control. Setting
the Flux valve control to “AUTO” closes the
flux valve relay when the Start button is
pressed, and opens the flux valve relay when
the last sequence is finished. The flux valve
control can be overridden by using the flux
button. Setting the flux valve control to “MAN”
requires the user to close and open the flux
valve relay with the flux button.
Wire Feed Speed Setting
Wire feed speed setting, indicated by “WFS”
in the upper display, can be set to “IPM” inches-per-minute or “MPM” meters-per-minute.
This setting is independent of the program selected.
6-8. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parameters, and to select various sequences. Refer to the section for
the function in question for information related to using the Adjust control.
1
6-9. Sequence Push Button
1
2
3
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LED’s
2
1
. For
more information on Setting Sequence Parameters See Section 8-1.
If zero time is programmed for a timed sequence except for Weld, that sequence will
be skipped.
• The Sequence push button allows the
selection of welding sequences. Five welding sequences are available. The default
sequence is the Weld sequence. The Weld
sequence is active upon power up. Three
welding sequence LEDs are located above
the Sequence push button: Start, Crater,
and Preflow/Postflow. The applicable LED
illuminates to indicate the active welding sequence.
• In the Weld sequence display mode, the Sequence push button LED is off. When the
Sequence push button is pressed, the Sequence push button flashes and the Start
LEDs flash. In this condition, the unit is in the
Start sequence display mode, and Start sequence parameters are shown in the displays.
Welding sequences other than weld must
be set prior to initiating the arc. When the
unit enters a welding state, all sequence display modes are terminated and the weld display mode is activated.
• When the Sequence push button pressed a
second time, the Crater sequence LED
flashes; the Sequence LED also remains
flashing. In this condition, the unit is in the
Crater sequence display mode, and the
Crater sequence parameters are shown in
the displays.
• When the Sequence push button is pressed
a third time, the Preflow/Postflow sequence
LED flashes. The Sequence push button
LED remains flashing. In the Preflow display mode, the upper display shows the preflow time, and PRE is shown in the lower
display. To change the preflow time, press
the upper display and turn the Adjust control.
To select between preflow (PRE) and postflow (POST), press the lower display button
and turn the Adjust control. When POST is
selected, the upper display is used to specify postflow time.
• When the Sequence button is pressed a
fourth time, the unit returns to the Welding
sequence display mode.
6-10. Flux Push Button
2
1
1
2
Flux Push Button
Flux Push Button LED
Pressing the Flux push button
toggles the flux valve control open
and closed. When the Flux push
button LED is lit, the flux valve control is open.
When the flux valve control is set to
“AUTO” (see Section 6-7), the flux
valve opens when the Start button
is pressed, and closes when the
last sequence is finished.
OM-212 296 Page 27
6-11. Auxiliary Menus
1
2
3
4
5
6
7
8
9
10
11
4
5
1
7
2
Program Display
Program Push Button
Sequence Push Button
Upper Display
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
Setup Push Button
Flux Push Button
Lock LED
6
10
3
9
11
8
Ref. 236 564-B
Auxiliary Menus (Continued)
• Auxiliary Menu
An auxiliary menu is provided when both
the Sequence and Setup buttons are
pressed simultaneously. The Setup and
Sequence button LEDs flash when in the
auxiliary menu. Press the Setup button to
scroll forward, or press the Sequence button to scroll backwards through the auxiliary menu.
. To
exit auxiliary menu at any time,
press Sequence and Setup simultaneously, or press the inch up or inch
down botton.
1
Code
Upon leaving the auxiliary menu, the user is
asked if a password code, indicated by
“CODE” in the top display, should be activated. By default, the code is off, indicated
by “OFF” in the lower display. The user may
enter a numerical password between 0 and
999 by turning the Adjust control. When the
user re-enters the auxiliary menu, the password code must be selected to gain access
to the auxiliary menu. A failed attempt returns the user to the weld screen and a
counter will increment. The counter in the
program display shows the number of incorrect attempts. The user has five attempts to enter the correct password code
before being locked out of the auxiliary
menu, indicate by “LOCK”, in the lower display. After five failed attempts, the power
may be cycled to continue welding, but the
user will remained locked out of the auxiliary menu. Pressing the Program, Sequence,
upper display, and Setup buttons simulta-
OM-212 296 Page 28
neously resets the counter to zero (0),as
shown in the weld screen. When the counter is reset,“CODE” is shown in the upper
display, and “RESET” in the lower display.
Pressing the Program, Sequence, upper
display, and Setup buttons simultaneously
again, will reset the unit to the factory defaults (see Section on Reset To Factory
Settings), indicated by “WIPE” in the upper
display. Resetting the unit will also turn off
the password code feature.
2
Voltage Range Lock
Amperage Range Lock
The amperage range lock is indicated by
“LOCK” in the upper display and a lit Amps
LED. The amperage range lock is set to off,
indicated by “OFF” in the lower display or
0.0 to 250 amperes. The amperage range
lock is program dependant and independent for wire feed speed or voltage lock.
. If locks are active, only those programs
with locks are accessible and the lock
LED will be on. To quickly enable or disable the locks for all programs, press
the upper and lower display push buttons at the same time.
Power Source Selection
The upper display shows “PSS”. The lower
display shows “ON” or “OFF”. Use Adjust
control to select “ON” or “OFF”.
3
4
5
Wire Feed Speed Range Lock
Voltage range lock is active when “LOCK”
is shown in the lower display and the Volts
LED is lit. The voltage range lock is off by
default, and is confirmed by “OFF” being
shown in the upper display. To set a voltage
variance between 0 to 10 volts from preset
voltage, press the upper display button and
rotate the Adjust control to the desired voltage. The voltage range lock is program dependent, a different voltage variance may
be locked in for each program and independent from the wire feed speed and amperage lock.
The wire feed speed range lock is indicated
by “LOCK” in the upper display and a lit
Wire Speed LED. The wire feed speed
range lock is off by default, and “OFF” is
shown in the lower display. To set a wire
feed speed variance between 0 to 250 ipm
(0 to 6.3 mpm) from the preset wire feed
speed, press the lower display button and
turn the Adjust control until the desired wire
feed speed variance is set. The wire feed
speed range lock is program dependent, a
different wire feed speed variance may be
set for each program and independent of
from voltage and amperage locks.
. If locks are active, only those programs
. If locks are active, only those programs
with locks are accessible and the lock
LED will be on. To quickly enable or disable the locks for all programs, press
the upper and lower display push buttons at the same time.
with locks are accessible and the lock
LED will be on. To quickly enable or disable the locks for all programs, press
the upper and lower display push buttons at the same time.
Auxiliary Menus (Continued)
• Auxiliary Menu (Continued)
6 Number of Programs
The number of programs is indicated by
“NUMB” is shown in the upper display and
“PROG” is shown in the lower display. The
active program number (1 through 12) is
shown in the Program display. Use the Adjust control to change the active program.
. If locks are active, only those programs
with locks are accessible and the lock
LED will be on. To quickly enable or disable the locks for all programs, press
the upper and lower display push buttons at the same time.
7 Wire Drive Motor Type
There are four types of motor drives available, RAD−400 with tach, RAD−400 without tach, RAD−780 with tach, and
RAD−780 without tach. When selecting the
RAD−400 with tach, ”RAD” will be displayed in the upper display and ”400” will be
displayed in the lower display. When selecting the RAD−780 with tach, ”RAD” will be
displayed in the upper display and ”780” will
be displayed in the lower display. When selecting the RAD−400 without tach or
RAD−780 without tach, ”NO” will be displayed in the upper display and ”TACH” will
be displayed in the lower display.
8 Wire Drive Motor Direction
The motor direction is indicated by ”MOTR”
is displayed in the upper display and ”RIGT”
or ”LEFT” is displayed in the lower display.
Changing between ”RIGT” and ”LEFT”
changes the direction of the motor.
9 Parallel Kits
The number of paralleling kits is indicated
by ”PRLL” in the upper display, ”KITS” in the
lower display, and the number of kits in the
Program Display. When paralleling two
power sources with a Miller Paralleling Kit,
select ”1” in the Program Display. When using one power source per HDC 1500DX,
set the number of paralleling kits to ”0” in the
Program Display.
10 SB1 and SB2 Relays
The contact closure of the SB1 and SB2 is
indicated by ”RLAY” in the upper display.
When the HDC 1500DX is powered off, the
SB1 and SB2 relay closures are open.
When the HDC 1500DX is powered on, if
”NOPN” is displayed in the lower display,
the SB1 and SB2 relay contact closures act
as normally−open. When the HDC 1500DX
is powered on, if ”NCLS” is displayed in the
lower display, the SB1 and SB2 relay contact closures act as normally−closed.
11 Motion Control
Motion control is indicated when “MOVE” is
shown in the lower display. Motion control
is used to set when SB1 engages. When
“BUTN’ is shown in the upper display, SB1
will engage when the start button is pressed
and preflux has timed out. When a positive
time is selected, SB1 will engage when the
selected time has elapsed after an arc is established. When a negative time is selected, SB1 will engage when the start button is pressed, but the weld sequence will
not start until the selected time has elapsed.
12 Arc Time
When “H1” is shown in the program display
the total number of arc hours is shown in the
lower display, wrapping to the upper display. When “H2” is shown in the program
display, the resettable number of arc hours
is shown in the lower display, wrapping to
the upper display. The resettable number of
arc hours “H2” is reset by pressing both the
upper and lower display buttons at the
same time. The total number of arc hours
“H1” cannot be reset. The number following
the decimal point in the lower display shows
the number of minutes.
13 Cycles
When “C1” is shown in the program display,
the total number of arc cycles is shown in
the lower display. wrapping to the upper display. When “C2” is shown in the program
display, the resettable number of arc cycles
is shown in the lower display, wrapping to
the upper display. The resettable number
of arc cycles “C2” is reset by pressing both
the upper and lower display buttons at the
same time. The total number of arc cycles
“C1” cannot be reset.
14 Software Revision Level
When “DREV” is shown in the upper display, control board PC20 revision level is
shown in the lower display. Press the upper
display button and “MERV” will now be displayed in the upper display, and the motor
control board PC1 revision level will be displayed in the lower display.
15 Reset To Factory Settings
To access reset menu and reset factory default settings, proceed as follows: simultaneously press the Program, Sequence, upper display, and setup buttons. “WIPE” is
displayed on the upper display, and “OFF”
is displayed on the lower display. The lower
display button LED is also lit. Turn Adjust
control or push lower display button to
change lower display from “OFF” to “ON”,
and simultaneously press the Program, Sequence, upper display, and setup buttons
again. All parameters except arc time and
cycle count are now reset to factory default
settings.
If a reset is not desired, turn Adjust control
until lower display shows”OFF”, and simultaneously press the Program, Sequence,
upper display, and setup buttons.
SECTION 7 − MOTOR TYPES
. For the HDC 1500DX to work properly, the motor used must match the motor selected.
The motor is selected in the Auxiliary Menu (see Section 6-11 on Wire Drive Motor Type).
Types of Motors supported by the HDC 1500DX.
Motor
Auxiliary Menu Selection
RAD 400 With Tachometer
RAD 400
RAD 780 With Tachometer
RAD 780
RAD 400 Without Tachometer
NO TACH
RAD 780 Without Tachometer
NO TACH
SAW 4
SAW 4
When using a motor With a Tachometer, the Wire Speed shown is the speed of the wire in either inches−per−minute or meters−per−minute (see
Section 6-7). The tachometer provides feedback to regulate and record wire speed.
When using the RAD 400 Without Tachometer or RAD 780 Without Tachometer, the Wire Speed shown is neither a wire speed in inches−per−
minute nor a wire speed in meters−per−minute, but rather a percentage of the power provided to the motor. Without a tachometer the HDC
1500DX is unable to either regulate or record wire speed.
OM-212 296 Page 29
SECTION 8 − SETTING SEQUENCE PARAMTERS
8-1. Sequence Parameters In A Program
. For more
information on Sequence push buttons, see Section 6-9.
If time is set to zero in Weld sequence, welding continues until
stop button is pressed.
Parameters
Sequence
Volts
(CV or CV+C)
Amps
(CV+C)
Wirespeed
(CV)
Seconds
1. Preflow
If time is set to zero in any timed sequence except Weld, the sequence
is skipped.
0.0-10.0
2. Run-In
X
3. Start
X
X
X
0.0-5.0
4. Weld
X
X
X
0.0-600.0
5. Crater
X
X
X
0.0-5.0
6. Burnback
X
X
X
0.0-5.0
7. Postflow
0.0-10.0
Weld Time
Crater Time
Preflow
Time
Start
Time
Burnback Time
Postflow TIme
Time
Preflow
Run-In Start
Start Button
OM-212 296 Page 30
Weld
Crater
Stop Button
Burnback Postflow
Sequence End
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
9-1. Routine Maintenance
!
Disconnect power before maintaining.
3 Months
Replace
cracked
parts.
Repair or
replace
cracked
weld
cable.
Clean and
tighten
weld
terminals.
Replace
unreadable
labels.
Check
14-pin
cord.
Check gas
hose and
fittings.
Check
gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
monthly.
OR
Clean
drive
rolls.
9-2. Circuit Breaker CB1
!
Turn Off welding power
source and weld control.
1
Circuit Breaker CB1
CB1 protects the HDC 1500DX internal circuits from overload. If CB1
opens, all operations stop. Correct
the problem, and press button to reset breaker.
1
Ref. 803 449-A
OM-212 296 Page 31
9-3. Troubleshooting Table
Trouble
Remedy
Unit is completely inoperative.
Check circuit breaker CB1, and reset if necessary (see Section 9-2).
Wire does not feed during jogging.
Place Power Switch S1 in On position (see Section 6-4).
Check 115 volts ac input power and be sure it is energized.
Check circuit breaker CB1, and reset if necessary (see Section 9-2).
Jog Speed Control set too low; increase Jog Speed setting (see Section 6-7).
Check wire feed motor, and repair or replace if necessary.
Check Inch Up push buttons PB3 and Inch Down push button PB4, and replace if necessary (see
Section 6-4 and Parts List).
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Wire feeds wrong direction during jogging.
Change Wire Drive Motor Direction setting in the Auxiliary Menu (see Section 6-11).
Wire only feeds down whether Inch
Down or Up button is pressed.
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Wire does not feed after Start button is
pressed (ensure that all wire feed jogging functions are operating properly
before checking this problem).
Check Start switch PB1, and replace if necessary.
No wire feed speed control with Wire
Speed control during welding. Wire
Speed remains at the Run−In Wire
Speed setting.
Check current feedback signal. This signal, +1 volt DC per 100 amperes, can be measured on terminal strip TB1, terminal F, with respect to terminal D (see Section 5-5). HDC 1500DX needs a signal of
greater than 1.5 volts DC i.e. > 150 amps) for the unit to go from run−in to weld parameters.
No contactor control for welding power
source (ensure that welding power
source is working properly and that all
connections are correct).
Check for contact closure from pin A to pin B. This can be measured on terminal block TB1, terminal
A, with respect to terminal B (see Section 5-5).
No output control for welding power
source.
Check command signal on pin E of 14-pin receptacle. This signal can be measured on terminal block
TB1, terminal E, with respect to terminal D. Signal should go from 0 to +10 volts DC as Output control
is turned from min. to max.
Unit displays BUTN EROR.
Check the push buttons, and replace if necessary (see Section 6-4 and Parts List). (On power up the
HDC 1500DX checks the push buttons to see if any are stuck.) Turn the unit off for 10 seconds to
clear the error message.
Unit displays TACH EROR.
Check connection from HDC 1500DX to motor. Turn the unit off for 10 seconds to clear the error message. This error is displayed because the HDC 1500DX is not receiving a tach signal from the motor.
The unit will not start if in a menu screen, indicated by a blinking light.
Have Factory Authorized Service Agent check control board PC1, and replace if necessary.
Make sure the motor being used matches the one selected in the Auxiliary Menu (see Section 6-11).
(The motor may not have a tach.)
Make sure motor cable is not routed with weld cable. (If inching works properly, noise may be corrupting the tach signal.)
Unit displays MOTR EROR.
Make sure the motor being used matches the one selected in the Auxiliary Menu (see Section 6-11).
Turn the unit off for 10 seconds to clear the error message.
Inspect motor for damage. (see motor Owner’s Manual). (Motor draws excessive amount of current.)
Erratic weld and no control of output.
OM-212 296 Page 32
Check remote voltage sense lead polarity, (see Section 5-3) for correct sense lead connections.
Trouble
Unit displays GRND EROR.
Remedy
Welding current is present in the safety ground. Isolate welding wire and torch from any grounded
equipment. Turn the unit off for 10 seconds to clear the error message.
Separate welding cables from control cables. (Noise is creating an excessive amount of current in the
safety ground.)
Unit displays COM EROR.
Make sure all connectors are properly plugged into both boards. (Motor board is not communicating to
Display board.)
Notes
OM-212 296 Page 33
SECTION 10 − ELECTRICAL DIAGRAM
238 416-A
Figure 10-1. Circuit Diagram
OM-212 296 Page 34
SECTION 11 − PARTS LIST
23
. Hardware is common and
24
not available unless listed.
1
22
21
3
2
20
4
5
19
6
18
17
16
12
7
13
9
15
10
14
11
8
803 627-D
Figure 11-1. Control Box Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1 Control Box Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
. . . . . . . . . . 214 799 . . . . .
. . . . . . . . . . 214 808 . . . . .
. . . . . . . . . . 179 851 . . . . .
. . PB3, 4 . 202 944 . . . . .
. . . PB1 . . 202 946 . . . . .
. . . PB2 . . 202 945 . . . . .
........................
. . . . S1 . . 011 611 . . . . .
. . . . . . . . . . 236 564 . . . . .
. . . . . . . . . . 240 509 . . . . .
. . . . . . . . . . 237 079 . . . . .
. . . . . . . . . . 221 404 . . . . .
. . . . . . . . . . 193 440 . . . . .
. . . . . . . . . . 214 816 . . . . .
. . . . . . . . . . 212 481 . . . . .
. . . . . . . . . . 214 805 . . . . .
. . . . . . . . . . 230 939 . . . . .
. . . PC1 . . 237 083 . . . . .
. . . RC2 . . 139 268 . . . . .
. . . RC1 . . 094 480 . . . . .
. . . RC3 . . 073 687 . . . . .
. . . . . . . . . . 070 371 . . . . .
. . . CB1 . . 083 432 . . . . .
Box, Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Box Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . .
Switch, Pb Mc No Spst 5A 115VAC (Gray) . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Pb Mc No Spst 5A 115VAC (Green) . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Pb Mc No Spst 5A 115VAC (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Dpdt 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overlay, Front Panel (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Display/Micro W/Program . . . . . . . . . . . . . . . . . . . . . . . .
XFMR, Control 30Va 24V/24V/18V/18V 115 Pri 50/60 . . . . . . . . . . . . . . . .
Switch, Ground Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, Terminal Strip Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block, Term 30 Amp 13 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Motor Control W/Program . . . . . . . . . . . . . . . . . . . . . . . .
Conn, Circ Ms/Met 10Skt Size 18 Rcpt Panel Solder . . . . . . . . . . . . . . . . .
Conn, Circ Ms/Met 14Pin Size 20 Rcpt Panel Solder . . . . . . . . . . . . . . . . .
Conn, Circ Ms/Met 4Skt Size 14S Rcpt Panel Solder . . . . . . . . . . . . . . . . .
Blank, Snap-In Nyl 1.093/1.125 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
OM-212 296 Page 35
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1 Control Box Assembly (Continued)
. . . 24 . . . . . . . . . . 117 860 . . . . . Blank, Snap-In Nyl .187 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . 039 116 . . . . . Label, High Voltage Test And Ground Ok . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 155 436 . . . . . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 236 767 . . . . . Label, CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 236 565 . . . . . Label, Warning Electric Shock Power Still Present . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 236 569 . . . . . Label, Rating Card CSA/CE 300438 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 236 226 . . . . . Label, Remote Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 212 591 . . . . . Cable, Motor 10 Ft (10 Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 178 836 . . . . . Cable, Interconnecting 30 Ft (14 Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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.
Notes
OM-212 296 Page 36
Effective January 1, 2008
(Equipment with a serial number preface of LJ 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
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller 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
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend
models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
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.
3.
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 2008-01
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.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
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.
PRINTED IN USA
© 2008 Miller Electric Mfg. Co. 2008−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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