Miller | LF153902 | Owner Manual | Miller INVISION 354MP CE User manual

Miller INVISION 354MP CE User manual
OM-196 596M
March 2005
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Stick (SMAW) Welding
Description
Arc Welding Power Source With Built-In
Synergic Control
Invision 354MP
R
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog 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 7/03
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 − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Weld Output Receptacles And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Optional 115 Volt AC Duplex Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Example Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Synergic Controls And Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Initial Display, Manual Pulse MIG Mode, MIG Mode, And Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Choosing Pulse Programs And Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. How Manual Pulsed MIG Waveform Components Affect Arc and Burn-off Rate . . . . . . . . . . . . . . . . . .
6-9. Overview Of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity For
European Community (CE) Products
Miller Electric Mfg. Co.
Manufacturer’s Name:
Manufacturer’s Address:
Declares that the product:
1635 W. Spencer Street
Appleton, WI 54914 USA
Invision 354MP
conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: December 1995
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
European Contact:
Telephone:
Fax:
dec_con1_11/02
Mr. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290-203
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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 electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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 after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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 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 Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read 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 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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-196 596 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-196 596 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, 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 Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
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.
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.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-196 596 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-196 596 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-196 596 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer 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 agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-196 596 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
D
D
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
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 N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique 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 imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives 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.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-196 596 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
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 l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-196 596 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − DEFINITIONS
3-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
1.2
1.3
2.1
2.2
2.3
2
2.1
2.2
2.3
3
3.1
3
3.1
3.2
3.2
3.3
3.3
4
5
4.1
+
4
+
+
+
4.1
6
5
6
S-179 310
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
1/96
OM-196 596 Page 9
1
1
2
3
4
5
6
V
V
> 60 s
V
S-185 836
7
8
9
10
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
3 Disconnect input plug or
power before working on
machine.
4 Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
5 Always wait 60 seconds after
power is turned off before
working on unit, OR
6 Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
7 When power is applied failed
parts can explode or cause
other parts to explode.
8 Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
9 Always wear long sleeves and
button your collar when
servicing unit.
10 After taking proper
precautions as shown,
connect power to unit.
1
1
2
3
∠ = <60 °
4
∠
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309-A
2
3
4
5
1/96
OM-196 596 Page 10
3-2. Manufacturer’s Rating Labels
CC/CE Models
CV/CE Models
217 201-B / 217 202-B
OM-196 596 Page 11
3-3. Symbols And Definitions
A
Panel
Alternating
Current (AC)
Output
Circuit Breaker
Remote
On
Off
Gas Tungsten Arc
Welding
Negative
Voltage Input
Direct Current
(DC)
Positive
Inductance
Protective Earth
(Ground)
Constant Current
Constant Voltage
Foot Control
Line Connection
Gas Metal Arc
Welding (GMAW)
Three Phase Static
Frequency ConverterTransformerRectifier
Shielded Metal Arc
Welding (SMAW)
Arc Force
U0
Rated No Load
Voltage (Average)
Hz
Hertz
U1
IP
Pulsed
I1max
V
Amperage
Rated Maximum
Supply Current
OM-196 596 Page 12
I1eff
Primary Voltage
Degree Of
Protection
U2
I2
Conventional
Load Voltage
Rated Welding
Current
X
%
Voltage
Duty Cycle
Percent
Lift-Arc Trigger
Hold Operation
(GTAW)
Single Phase
Three Phase
Maximum Effective
Supply Current
Increase
Lift-Arc Operation
(GTAW)
SECTION 4 − INTRODUCTION
4-1. Specifications
Rated Welding
Output
300 A @
32 Volts DC,
60% Duty Cycle
Voltage
Range
(CC/CV
Models
Only)
Amperage
Range
10 − 35
5 − 400
Maximum
Open-Circuit
Voltage DC
IP Rating
90
23
Amperes Input
at Rated Load
Output 50/60 Hz
400 V
KVA
KW
17.0
(0.15*)
12.4
(0.09*)
11.5
(0.04*)
*While idling
4-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 7-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
60% Duty Cycle
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95 / SA-178 651
OM-196 596 Page 13
4-3. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
CC Mode
CV Mode
va_curve1 4/95 − SA-188 537 / SA-178 653
Notes
OM-196 596 Page 14
SECTION 5 − INSTALLATION
5-1. Selecting A Location
24 in
(610 mm)
Dimensions And Weight
76 lb (34.6 kg)
17 in
(432 mm)
12-1/2 in
(318 mm)
1
Movement
Lifting Handles
Use handles to lift unit.
2
Y Do not move or operate unit
where it could tip.
1
Hand Cart
Use cart or similar device to move
unit.
3
Rating Label
Use rating label to determine input
power needs.
1
2
4
Line Disconnect Device
Locate unit near correct input
power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Location
4
18 in
(460 mm)
3
18 in
(460 mm)
loc_2 3/96 - Ref. ST-151 556 / ST-802 167
OM-196 596 Page 15
5-2. Weld Output Receptacles And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
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.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
+
−
10 − 100% Duty Cycle
Output Receptacles
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-196 596 Page 16
S-0007-F−
5-3. Remote 14 Receptacle Information
Socket*
A
B
K
J
24 VOLTS AC
I
H
C L N
D M
G
E F
115 VOLTS AC
REMOTE
OUTPUT
CONTROL
A/V
AMPERAGE
VOLTAGE
GND
Socket Information
A
24 volts ac. Protected by circuit breaker CB2.
B
Contact closure to A completes 24 volts ac
contactor control circuit.
I
115 volts ac. Protected by circuit breaker CB1.
J
Contact closure to I completes 115 volts ac
contactor control circuit.
C
Output to remote control; +10 volts dc.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
F
Current feedback; +1 volt dc per 100 amperes.
H
Voltage feedback; +1 volt dc per 10 output receptacle volts.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
*The remaining sockets are not used.
5-4. Optional 115 Volt AC Duplex Receptacle And Circuit Breakers
1
115 V 7 A AC Receptacle
Power is shared between duplex
receptacle and Remote 14 receptacle (see Section 5-3).
2
Circuit Breaker CB1
CB1 protects duplex receptacle
and 115 volt ac portion of Remote
14 receptacle from overload.
1
3
Circuit Breaker CB2
CB2 protects 24 volt ac portion of
Remote 14 receptacle from
overload.
Press button to reset breaker.
2
3
ST-801 245-A
OM-196 596 Page 17
5-5. Electrical Service Guide
NOTE
Actual input voltage should not exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, output may not be available.
Input Voltage
400
Input Amperes At Rated Output
17.0
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Reference: 1996 National Electrical Code (NEC).
Notes
OM-196 596 Page 18
30
S-0092J
5-6. Connecting 3-Phase Input Power
Y Installation must meet all National
and Local Codes − have only qualified persons make this installation.
Y Disconnect and lockout/tagout input power before connecting input
conductors from unit.
3
= GND/PE Earth Ground
4
Y Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
For Three-Phase Operation
1
2
7
3
4
2
5
6
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
L1
3
L2
L3
6
5
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7
Overcurrent Protection
Select type and size of overcurrent protection using Section 5-5 (fused disconnect
switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
1
Tools Needed:
2/04 - Ref. 802 136-A / 801 192
OM-196 596 Page 19
SECTION 6 − OPERATION
6-1. Front Panel Controls
1
Power Switch
amperage.
. The
fan motor is thermostatically
controlled and only runs when cooling is
needed.
2 Voltmeter (see Section 6-2)
3 Ammeter/Trim Indicator (see Section
6-2)
4 Ammeter Light
Lights when display beneath is indicating
5
7
Trim Indicator Light
Lights when display beneath is indicating
trim.
6
Output Adjust Control
Controls various output values, depending
on mode being used.
4
1
10
Increment Push Button (see Section
6-4)
8 Decrement Push Button (see Section
6-4)
9 Display (see Section 6-4)
10 Select Push Button (see Section 6-4)
5
6
3
2
9
8
7
Ref. 193 785
OM-196 596 Page 20
6-2. Meter Functions
NOTE
Mode
The meters display the actual weld output values for approximately three seconds
after the arc is broken.
Meter Reading At Idle
V
MIG
A
V
24.5
250
Preset Volts
Blank
Actual Volts
Actual Amps
V
Trim
V
A
24.5
250
Blank
Pulse Display
Actual Volts
Actual Amps
V
A
V
A
Blank
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
24.5
Pulsed
MIG
50
Stick−
Contactor Remote
Stick−
Contactor ON
Manual
Pulse
Meter Reading While Welding
85
80.0
85
24.5
24.5
A
85
85
Actual Volts (OCV)
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
PPS
200
Pulses Per Second
24.5
Actual Volts
85
Actual Amps
OM-196 596 Page 21
6-3. Example Displays
. Values shown are hypothetical.
The “A” (Amperage) and “Trim” lights illuminate as shown.
Amperage preset display for Stick welding mode.
Voltage preset display for MIG welding mode.
Display while welding.
Preset trim display for Pulse welding mode.
Preset pulses per second (PPS) display for Manual Pulse welding mode.
NOTE
OM-196 596 Page 22
The Stick mode provides the Adaptive Hot Start™ feature, which automatically
increases the output amperage at the start of a weld should the start require it. This
eliminates electrode sticking at arc start.
6-4. Synergic Controls And Overview
Controls
1
Display
2
Parameter Select Push Button
Press button to move > on display.
The parameter indicated by > is
selected.
3
3
2
Increment Push Button
Press increment button to increase
selected parameter.
4
Decrement Push Button
Press decrement button
decrease selected parameter.
to
See example at left.
Overview
The built-in synergic control provides four modes of operation:
1
4
Manual Pulse MIG − control functions as a discrete pulsed MIG CC
control.
Mig − control functions as a remote
voltage control.
Stick − unit is placed in CC mode for
SMAW welding.
Example
To select Program 7, set to Non Adaptive, and set Arc Length to 36, proceed as follows:
Select top line by pressing
Select push button until > is
on top line. Press Increment
button until Program 7 appears.
Press Select push button to
select third line, and press Increment or Decrement button
so Non Adaptive appears.
> P r g
7
S t
1 . 0 mm
Synergic Pulser − programs that
use factory-entered values are
used to control process.
Setup screens (see Section 6-6) allow programs or modes to be made
inaccessible (locked out) to the operator, and the language used in the
displays (English, French, etc.) to
be defined.
9 8 A r / 2 O 2
A d a p t i v e
P u l s e
P r g
1 . 0 mm
7
S t
9 8 A r / 2 O 2
> N o n − A d a p t i v e
P u l s e
Turn Output Adjust control to
set arc length to 36.
36
OM-196 596 Page 23
6-5. Initial Display, Manual Pulse MIG Mode, MIG Mode, And Stick Mode
1
I N V I S I ON
3 5 4 MP
C O P Y R I GH T
(C)
2
1 9 9 9
M I L L E R
E l e c t r i c
M f g.
X X X X X X
C o.
With > on top line,
press Increment or
Decrement button until
Manual Pulse MIG appears.
Display scrolls to
show lines 5 and 6.
> P r g 2 3
M a n u a l
Select top line of display, and press
Increment or Decrement button until Manual Pulse MIG is displayed.
Select Amps Peak line, and use Increment or Decrement button to set
peak amperage from 100−400
amps, but always at least 1 amp
more than background amperage.
P u l s e
3 4 6
A m p s
P e a k
7 8
A m p s
B a c k g r o u n d
1 . 7 3
m s
7 8
A m p s
1 . 7 3
m s
4 0 0
P u l s e
W i d t h
B a c k g r o u n d
P u l s e
A m p s
Manual Pulse MIG Mode
The synergic control functions as a
discrete pulsed MIG CC control in
this mode.
1
2
Software Program Number
When power is applied, initial display with software number appears
momentarily, and then last program
to be viewed before control was
shut down appears.
W i d t h
S t a r t
Select Amps Background line, and
use Increment or Decrement button
to set background amperage (min:
10 amps; max: 300 amps, but always at least 1 amp less than peak
setting).
Select ms Pulse Width line, and use
Increment or Decrement button to
set pulse width (1 - 5 ms, but max
setting may be less depending on
Frequency setting).
Select Amps Start line, and use Increment or Decrement button to set
starting amperage (150 - 530 amperes). This amperage value is
used at the start of the weld or when
an arc is restarted.
Use Output Adjust control to set
pulse frequency. The range is 30 300 pulses per second, but max
setting may be less depending on
Pulse Width setting.
3
MIG Mode
The synergic control provides voltage control.
3
With > on top line,
press Increment or
Decrement button until
MIG appears.
> P r g 2 4
3 0 %
M I G
I n d u c t a n c e
Select top line of display, and press
Increment or Decrement button until MIG is displayed. Select Inductance line, and use Increment or
Decrement button to set inductance
(0−100% in increments of one). Use
Output Adjust control to set voltage
value (10−35 volts).
4
Stick Mode
In the Stick mode, the user can select contactor control (remote or
On) and the Dig value.
4
With > on top line,
press Increment or
Decrement button until
STICK appears.
OM-196 596 Page 24
> P r g 2 5
S T I C K
C o n t a c t o r
2 5 %
D I G
R E MO T E
Select contactor control line and
press Increment or Decrement button to select Remote contactor control or On. The contactor is On at all
times when On is selected.
Select Dig line, and and use Increment or Decrement button to set
Dig value (min: 0%; max: 100%).
Dig helps arc starting and reduces
sticking while welding. The higher
the dig value defined, the more the
short-circuit amperage increases at
low arc voltage.
6-6. Setup Screens
To access Setup screens: turn
welding power source Off, press
and hold Select push button, turn
unit On, and hold push button down
until initial screen leaves.
To exit Setup screens, turn welding
power source Off and then On
again. Parameters that are displayed when the Setup screens are
exited are active.
1
S e t u p
A c c e s s i b l e
M a n u a l
P u l s e
> O f f
2
S e t u p
L a n g u a g e
> E n g l i s h
P r o g r a m s
M i g
1
Accessible Programs Screen
Select second line of display, and
press Increment or Decrement button until Accessible Programs is
displayed.
Select third line of display and press
Increment or Decrement button to
access each program and the three
modes as desired. Select the fourth
line and press Increment or Decrement button to define each option
On (accessible) or Off (not accessible).
Programs and modes that are defined Off are not shown when the
operator scrolls through the displays in normal operation.
2
Language Screen
Select second line of display, and
press Increment or Decrement button until Language is displayed. Select third line of display and press
Increment or Decrement button until desired language is shown. The
choices are English, French, Italian, Spanish, and German.
OM-196 596 Page 25
6-7. Choosing Pulse Programs And Setting Parameters
Choosing Pulse Program:
Pulse programs are pre-written and cannot be
changed by the user. See Section 6-9 for program
parameters and recommended gas mixtures.
Choose program depending on the type and size of
wire, and type of shielding gas used. For example,
the program shown below is for 1.2 mm steel wire
using 80 Ar / 20 CO2 gas.
> P r g
2
S t
1 . 2 mm
8 0 A r / 2 0 C O 2
A d a p t i v e
P u l s e
Choosing Adaptive Or Non Adaptive:
Setting Arc Length:
Adaptive: Pulse frequency is automatically regulated
to maintain a constant arc length, regardless of
changes in wire stickout.
Arc length is adjusted with the Output Adjust control. Displayed preset Trim values (0 − 100) are for reference
only.
Non Adaptive: Constant pulse frequency is maintained, regardless of the arc length.
Adjustment normally needed if wire feed speed or type of
weld joint is changed.
Choose mode which best applies to your
application.
Set arc length that best applies to your application.
OM-196 596 Page 26
6-8. How Manual Pulsed MIG Waveform Components Affect Arc and Burn-off Rate
Changes to Arc
A
Comments
A Electrode extension (stickout)
B Arc length
Reference Waveform
T
A
T
Increase Peak Amperage Only
A
Decrease Peak Amperage Only
T
A
Increase Background Amperage Only
A
Decrease Background Amperage Only
T
T
A
Increase Pulse Width (TIme) Only
A
Decrease Pulse Width (Time) Only
T
C Contact tube-to-work distance should be 3/8 in to
3/4 in. Recommended gun angle is 10 to 20 degrees from vertical.
Increasing peak amperage only:
Increases burn-off rate, which directly affects
arc length
Increases average amperage slightly
Increase heat input slightly
Note: A good fine tuning parameter for arc length.
Assuming a constant pulse width (peak time), peak amperage should be high enough to achieve a spray transfer. Too low of a peak current often results in a globular
transfer. High peak amperages result in smaller droplets, and a more forceful or driving arc.
Increasing background amperage only:
Increases arc length
Increases average amperage
Increases heat input and penetration
Increases puddle fluidity
Note: This current level is largely responsible for arc
stabilization, and must be high enough to maintain the
arc between peak current pulses.
Increasing pulse width (time) only:
Increases arc length
Increases heat input and penetration
Increases arc cone width
Increase average amperage
T
A
Increasing pulses per second only:
Increase arc length
Increases average amperage
Increases heat input
Increase Pulses Per Second Only
T
A
Decrease Pulses Per Second Only
T
Note: A good fine tuning parameter for arc length.
Typically this variable is adjusted to control the Burn off
rate of the wire as it is fed into the arc.
OM-196 596 Page 27
6-9. Overview Of Programs
Program #
Wire Type
Wire Size
Shielding Gas
Meters Per
Minute: Min
Meters Per Minute: Max
1
Steel
1.0 mm
80% Argon/20% CO2
3.05
19.05
2
Steel
1.2 mm
80% Argon/20% CO2
2.54
11.43
3
Steel
1.0 mm
93% Argon/5% CO2/2% O2
2.03
19.81
4
Steel
1.2 mm
93% Argon/5% CO2/2% O2
2.54
12.70
5
Steel
1.0 mm
83% Argon/15% CO2/2% O2
3.05
19.05
6
Steel
1.2 mm
83% Argon/15% CO2/2% O2
2.54
11.43
7
Steel
1.0 mm
98% Argon/2% O2
2.03
19.81
8
Steel
1.2 mm
98% Argon/2% O2
2.54
12.70
9
Stainless Steel 308
0.8 mm
98% Argon/2% CO2
3.81
17.27
10
Stainless Steel 308
1.0 mm
98% Argon/2% CO2
2.54
19.81
11
Stainless Steel 308
1.2 mm
98% Argon/2% CO2
2.49
15.49
12
Stainless Steel 309
0.8 mm
98% Argon/2% CO2
3.81
17.27
13
Stainless Steel 309
1.0 mm
98% Argon/2% CO2
2.54
19.81
14
Stainless Steel 309
1.2 mm
98% Argon/2% CO2
2.49
15.49
15
Stainless Steel 316
0.8 mm
98% Argon/2% CO2
3.81
17.27
16
Stainless Steel 316
1.0 mm
98% Argon/2% CO2
2.54
19.81
17
Stainless Steel 316
1.2 mm
98% Argon/2% CO2
2.49
15.49
18
Aluminum 5356
1.0 mm
Argon
2.49
15.19
19
Aluminum 5356
1.2 mm
Argon
2.49
14.94
20
Aluminum 4043
1.0 mm
Argon
2.49
15.19
21
Aluminum 4043
1.2 mm
Argon
2.79
15.39
22
Metal Cored
1.2 mm
80% Argon/20% CO2
2.54
13.97
OM-196 596 Page 28
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
. Maintain more often
Y Disconnect power
before maintaining.
during severe conditions.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Damaged Or
Unreadable
Labels
Replace Cracked
Torch Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
7-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
ST-802 167
OM-196 596 Page 29
7-3. Voltmeter/Ammeter Help Displays
1
2
3
4
5
V
A
HE.L
P−0
V
A
HE.L
P−1
V
A
HE.L
P−2
V
A
HE.L
P−3
V
A
HE.L
P−4
. All directions are in reference to the front
of the unit. All circuitry referred to is located inside the unit.
1 Help 0 Display
Indicates a shorted thermistor RT2 on the left
side of the unit. If this display is shown, contact a Factory Authorized Service Agent.
2 Help 1 Display
Indicates a malfunction in the primary power
circuit. If this display is shown, contact a Factory Authorized Service Agent.
3 Help 2 Display
Indicates a malfunction in the thermal
protection circuitry located on the left side of
the unit. If this display is shown, contact a
Factory Authorized Service Agent.
4 Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
OM-196 596 Page 30
6
7
8
9
10
V
A
HE.L
P−5
V
A
HE.L
P−6
V
A
HE.L
P−7
V
A
HE.L
P−8
V
A
HE.L
P−9
fan to cool it (see Section 4-2). Operation will
continue when the unit has cooled.
shown, have an electrician check the input
voltage.
5
8 Help 7 Display
Indicates that the input voltage is too high
and the unit has automatically shut down.
Operation will continue when the voltage is
within the acceptable upper range limit (15%
above the applicable input voltage). If this
display is shown, have an electrician check
the input voltage. Help 7 can also indicate a
bus voltage imbalance.
Help 4 Display
Indicates a malfunction in the thermal
protection circuitry located on the right side
of the unit. If this display is shown, contact a
Factory Authorized Service Agent.
6
Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-2). Operation will
continue when the unit has cooled.
7
Help 6 Display
Indicates that the input voltage is too low and
the unit has automatically shut down. Operation will continue when the voltage is within
the acceptable lower range limit (15% below
the applicable input voltage). If this display is
9 Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. If this display is
shown, contact a Factory Authorized Service Agent.
10 Help 9 Display
Indicates a shorted thermistor RT1 on the
right side of the unit. If this display is shown,
contact a Factory Authorized Service Agent.
7-4. Error Codes
1
2
Program CRC Error
Program Range Error
If either error code appears, reset
the display to factory settings as follows:
1
Press Parameter Select push button or turn welding power source
Off and back On. Change settings
and continue.
E R R OR
P r o g r a m
M e m o r y
P r e s s
C R C
W i l l
B e
R e s e t
P a r m.
S e l e c t
2
E R R OR
P r o g r a m
M e m o r y
P r e s s
R a n g e
W i l l
B e
R e s e t
P a r m.
S e l e c t
7-5. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-6).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-6).
Check for proper input power connections (see Section 5-6).
No weld output; meter display On.
Input voltage outside acceptable range of variation (see Section 5-5).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-2).
If unit contains optional ground current sensor, excessive current in the ground circuit may have been
detected. Have electrician check input power circuit.
Erratic or improper weld output.
Check to make sure correct program is selected for welding wire and shielding gas used.
Use proper size and type of weld cable (see Section 5-2).
Clean and tighten all weld connections.
No 115 volts ac output at duplex receptacle, Remote 14 receptacle.
Reset circuit breaker CB1 (see Section 5-4).
No 24 volts ac output at Remote 14 receptacle.
Reset circuit breaker CB2 (see Section 5-4).
OM-196 596 Page 31
SECTION 8 − ELECTRICAL DIAGRAM
197 557
Figure 8.1. Circuit Diagram For Welding Power Source
OM-196 596 Page 32
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
SECTION 9 − PARTS LIST
. Hardware is common and
not available unless listed.
802 453-B
Figure 9-1. Parts Assembly
OM−196 596 Page 34
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . +175 148
. . . . . . . . . . . . . . . . . . . . . 175 256
. . . 2 . . . . . . . . . . . . . . . 195 585
. . . 3 . . . . . . . . . . . . . . . 179 309
. . . 4 . . . . . HD1 . . . . . 189 567
. . . . . . . . . . PLG9 . . . . 130 204
. . . 5 . . . . . . . . . . . . . . . 194 546
. . . 6 . . . . . . . . . . . . . . . 175 139
. . . 7 . . . . . . . . . . . . . . . 181 853
. . . 8 . . . . . D1,2 . . . . . 201 531
. . . 9 . . . . . . . . . . . . . . . 179 276
. . . 10 . . . C5,6 R1 . . . 175 194
. . . 11 . . . . RT1,2 . . . . 173 632
. . . 12 . . . . . . . . . . . . . . . 185 836
. . . 13 . . . . . . . . . . . . . . +183 551
. . . 14 . . . . . . . . . . . . . . . 604 176
. . . 15 . . . . . . . . . . . . . . . 182 445
. . . 16 . . . . . CB1 . . . . . 161 078
. . . 17 . . . . . CB2 . . . . . 083 432
. . . 18 . . . . . . . . . . . . . . . 175 147
. . . 19 . . . . . . . . . . . . . . . 213099
. . . . . . . . . . . . . . . . . . . . . 178 563
. . . . . . . . . . . . . . . . . . . . . 186 439
. . . 20 . . . . . . . . . . . . . . . 183 309
. . . 21 . . . . . . . . . . . . . . . 175 282
. . . 22 . . . . . . . . . . . . . . . 210346
. . . 23 . . . . . . . . . . . . . . . 175 138
. . . 24 . . . . . . . . . . . . . . . 192 853
. . . 25 . . . . . PC1 . . . . . 215 042
. . . . . . . . . . PLG2 . . . . 131 056
. . . . . . . . . . PLG3 . . . . 130 203
. . . . . . . . . . PLG4 . . . . 115 094
. . . . . . . . . . PLG5 . . . . 115 091
. . . . . . . PLG6, PLG8 . 131 054
. . . . . . . . . . PLG7 . . . . 115 093
. . . . . . . . . . PLG9 . . . . 131 204
. . . . . . . . . . PLG10 . . . . 166 680
. . . 26 . . . . RC10 . . . . 166 679
. . . 27 . . . . . . T2 . . . . . . 195 829
. . . 28 . . . . . . . . . . . . . . . 183 549
. . . 29 . . . . . . . . . . . . . . +207 727
. . . 30 . . . . . . . . . . . . . . . 153 403
. . . 31 . . . . . . . . . . . . . . . 177 547
. . . 32 . . . . . CT1 . . . . . 175 199
. . . 33 . . . . . . . . . . . . . . . 025 248
. . . 34 . . . . . C1 . . . . . 188 446
. . . 35 . . . . . C3,4 . . . . . 192 935
. . . 36 . . . . . PC2 . . . . +212 210
. . . . . . . . . . PLG13 . . . . 131 204
. . . . . . . . PLG14,21 . . 115 093
. . . 37 . . . . . . T3 . . . . . . 182 108
. . . 38 . . . . . . . . . . . . . . . 175 140
. . . . . . . . . . . . . . . . . . . . . 181 197
. . . 39 . . . . . . . . . . . . . . . 175 482
. . . 40 . . . . . . . . . . . . . . . 109 056
. . . 41 . . . . . SR1 . . . . . 179 629
. . . 42 . . . . PM1,2 . . . . 208 173
. . . 43 . . . . . . Z1 . . . . . . 173 570
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, caution falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSDUCER, current 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, output rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT DIODE, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole . . . . . . . . . . . . . . . . . . .
RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, str dx grd SP3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . .
NUT, 1.000 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, man reset 1P 7A 250VAC . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, man reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, nylon 1.000 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, bushing .750 NPT x 1.000 NPT . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, ident rear w/aux (order by model and serial number) . . . . . . . . .
COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, pwr 6mm 4/c 4m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg contactor/capacitor/PC Board . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC6, RC8) . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl .750 ID x 1.000mtg . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.125mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, insul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp film .5uf 900VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 2700uf 450VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD, interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS (RC2) (RC3) . . . . . . . . . . . . . . . . . . . . . . . . .
CHOKE, common mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, DI/DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT DIODE, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
2
1
1
1
1
4
2
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
2
1
2
1
1
2
1
1
1
2
2
1
1
1
OM-196 596 Page 35
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Parts Assembly (continued)
. . . 44 . . . . . . L1 . . . . . . 173 563 . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . 207 725 . . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . T1 . . . . . . 179 616 . . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . 207 467 . . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . 175 255 . . INSULATOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . . 173 693 . . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 50 . . . . . . . . . . . . . . . 176 736 . . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 51 . . . . . . . . . . . . . . . 175 132 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . PC3 . . . . . 196 165 . . CIRCUIT CARD, front panel display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 199 053 . . GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG11 . . . . 115 091 . . CONNECTOR & SOCKETS (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG17, PLG18 131 054 . . CONNECTOR & SOCKETS (RC4) (RC5) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 53 . . . . . FM . . . . . 175 084 . . FAN, muffin 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . RC1 . . . . . 189 886 . . RECEPTACLE, w/leads & plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . . 178 548 . . TERMINAL, connector friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 56 . . . . . C7,8 . . . . . 186 543 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 57 . . . . . . . . . . . . . . . 187 896 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . . 129 525 . . RECEPTACLE, twlk insul fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . . 193 785 . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . . 174 715 . . KNOB, pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 167 633 . . WASHER, shldr nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 188 308 . . WASHER, flat nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 159 264 . . RING, rtng ext .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . 175 855 . . DOOR, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . . 153 169 . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 63 . . . . . . . . . . . . . . . 176 226 . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . S1 . . . . . 128 756 . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . 179 310 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 66 . . . . . PC6 . . . . . 185 697 . . CIRCUIT CARD, filter board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 187 219 . . SPACER, nylon .203 OD x .375 ID x .750 lg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . 187 146 . . BRACKET, mtg filter bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . . 199 840 . . BUS BAR, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 115V Aux Power Option.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM−196 596 Page 36
Notes
Start Your Professional
Welding Career Now!
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1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 1/05
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2005 Miller Electric Mfg. Co.
1/05
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