Miller | MA020053B | Owner Manual | Miller MILLERMATIC 350 User manual

Miller MILLERMATIC 350 User manual
OM-1327
213 814AA
2009−10
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
Millermatic 350 And
Millermatic 350P
R
Visit our website at
www.MillerWelds.com
File: MIG (GMAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Installing Welding Gun/Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Connecting Spoolmatic) 15A Or 30A Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Installing Wire Spool and Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Selecting Input Voltage (200/230/460 Volt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Selecting A Location And Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Selection A Location And Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18. Threading Welding Wire For MIG Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro . . . . . . . . . . . .
3-20. Threading Welding Wire Through XR Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. MIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Weld Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. MIG Gun-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Pulse MIG Mode Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Pulse MIG Gun-On-Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Tip Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Weld Parameters For MIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Weld Parameters For Pulse Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
9
9
11
11
11
12
12
13
13
14
15
16
17
18
19
19
20
21
21
22
23
24
25
26
26
26
26
27
27
27
27
27
28
29
TABLE OF CONTENTS
SECTION 5 − PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. MIG Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Pulse MIG Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill . . . . . . . . . . . . . . . . . . . . . . .
5-5. Setting Hot Start (Aluminum Pulse Only) Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Setting Crater Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Recommended Crater Fill Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. System Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Motor Calibration Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Set Up Push Motor Torque (SUP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
30
30
31
32
33
34
35
36
38
39
40
41
41
41
42
43
44
46
48
50
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2009−08
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-1327 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-1327 Page 2
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect ImplantedMedical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-1327 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-1327 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2009−08
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-1327 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-1327 Page 6
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester
à distance.
D Les porteurs d’implants médicaux doivent consulter
leur médecin et le fabricant du dispositif avant de s’approcher
de la zone où se déroule du soudage à l’arc, du soudage
par points, du gougeage, de la découpe plasma
ou une opération de chauffage par induction.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-1327 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
OM-1327 Page 8
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global
Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-1327 Page 9
OM-1327 Page 10
.
A complete Parts List is available at www.MillerWelds.com
SECTION 3 − INSTALLATION
3-1. Specifications
Max. Open
Circuit
Voltage
Rated Output
300 A at
32 VDC,
60% Duty
Cycle
350 A at
32 VDC,
40% Duty
Cycle
Amps Input at Rated Output
60 Hz
90
200 V
230 V
460 V
575V
KVA
KW
Single-Phase
69
(1.7*)
61
(1.5*)
30
(0.75*)
24
(0.5*)
13.1
11.2
Three-Phase
34
(1.7*)
30
(1.5*)
15
(0.75*)
12
(0.5*)
11.6
11.5
* While idling
Wire Type and Diameter
Wire Feed Speed
Solid Steel
Stainless Steel
Aluminum
.023 − .045 in.
(0.8 − 1.1 mm)
.030 − .045 in.
(0.8 − 1.1 mm)
.035 − .047 in.
(0.9 − 1.2 mm)
50−700 IPM
(1.3−17.8 m/min)
Operating Temperature Range: −20C to +40C
Dimensions
Net Weight
H: 34 in. (864 mm)
W: 19 in. (483 mm)
D: 41 in. (1041 mm)
181 lb
(82 kg)
Storage Temperature Range: -30C to + 50C
3-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
WELDING AMPERES
500
400
If unit overheats, thermistors open,
output stops, and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
300
250
225
200
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
150
100
10
15
20
25 30
40
% DUTY CYCLE
60% Duty Cycle At 300 Amperes
6 Minutes Welding
50 60 70 80 90 100
40% Duty Cycle At 350 Amperes
4 Minutes Resting
4 Minutes Welding
6 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95 / 217 442-A
OM-1327 Page 11
.
A complete Parts List is available at www.MillerWelds.com
3-3. Volt-Ampere Curve
1
MAXVOLTS
MINVOLTS
90
80
Normal Volt-Ampere Curves
The volt-ampere curves show the
normal minimum and maximum
voltage and amperage output
capabilities of the welding power
source. Curves of other settings fall
between the curves shown.
70
VOLTAGE
60
50
40
30
20
10
0
0
50
100
150
200
AMPERAGE
250
300
350
217 443-A
3-4. Connecting To Weld Output Terminals
1
4
Do not place
anything between
weld cable terminal
and copper bar.
2
Tools Needed:
3
3/4 in. (19 mm)
803 778-A
Correct Installation
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.
OM-1327 Page 12
1 Weld Output Terminal
2 Supplied Weld Output Terminal Nut
3 Weld Cable Terminal
4 Copper Bar
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld
Incorrect Installation
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar. Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.
.
A complete Parts List is available at www.MillerWelds.com
3-5. Installing Work Clamp
1
2
Work Cable
Boot
Route cable through front panel
opening. Slide boot onto work
cable.
3
Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.
Close door.
1
2
3
Tools Needed:
3/4 in.
803 540-C
3-6. Installing Welding Gun/Cable Holder
1
2
3
2
Welding Gun/Cable Holder
Wrapper
Screw Locations
Remove screws from side panel.
Place holder against side panel and
align screw holes. Secure holder to
side panel with the previously
removed screws.
3
1
Ref. 803 545-D / Ref. 803 539-C
OM-1327 Page 13
.
A complete Parts List is available at www.MillerWelds.com
3-7. Installing Welding Gun
1
2
3
Drive Assembly
Gun Securing Knob
Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
4
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
4
1
2
3
Ref. 803 541-C
OM-1327 Page 14
.
A complete Parts List is available at www.MillerWelds.com
3-8. Connecting Spoolmatic) 15A Or 30A Gun
1
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
2
3
Weld Cable
Shielding Gas Hose
Route weld cable and gas hose
through opening in front panel.
4
Positive Weld Output Terminal
Connect weld cable to weld output
terminal.
5
1
2
Regulator/Flowmeter
Route shielding gas hose through
wire drive compartment, out
opening in rear panel, and up to
regulator/flowmeter. Connect gas
hose to regulator/flowmeter.
3
2
5
3
4
Î
Î
Tools Needed:
3/4, 5/8 in.
803 568-D
OM-1327 Page 15
.
A complete Parts List is available at www.MillerWelds.com
3-9. Connecting XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro
. XR Edge guns prior to serial no.
LE079101 require an adapter
cord (part no. 195 498).
1
2
3
Gun End
Gun Liner
Wire Outlet Guide
Trim excess liner from end of gun
so no more than 3/32 in. (2.4 mm) of
liner extends past wire outlet guide.
4
Gun Securing Knob
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
5
1
Be sure to change drive rolls to the
proper size and type.
5
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
. Be sure to trim liner to proper extension.
3/32 in.
(2.4 mm)
2
3
4
803 569-C / Ref. 803 570 -C / Ref. 803 463
OM-1327 Page 16
.
A complete Parts List is available at www.MillerWelds.com
3-10. Setting Gun Polarity For Wire Type
Changing Polarity
Wire Drive
Assembly Lead
1
Polarity Changeover Information
Always read and follow manufacture’s
recommended polarity.
Work Clamp Lead
D
1
D
+ Positive
Terminal
-
Negative
Terminal
Shown as shipped − Electrode Positive (DCEP): For
solid steel, stainless steel, aluminum, or flux core with
gas wires (GMAW).
Electrode Negative (DCEN): Reverse lead connections
at terminals from that shown above for gasless flux core
wires (FCAW). Drive assembly becomes negative.
3/4, 11/16 in.
Ref. 803 541-A
OM-1327 Page 17
.
A complete Parts List is available at www.MillerWelds.com
3-11. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
1
2
3
4
7
5
Argon Gas Or Mixed Gas
1
Cap
2
Cylinder Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
1
2
3
Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on
rear of welding power source.
7
8
9
CO2 Gas
Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s
recommended
flow rate.
8
9
CO2 Adapter (Customer
Supplied)
O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
cylinder.
6
Rear Panel
Tools Needed:
1-1/8, 5/8 in.
803 542-C
OM-1327 Page 18
.
A complete Parts List is available at www.MillerWelds.com
3-12. Installing Wire Spool and Adjusting Hub Tension
Use compression spring with
8 in (200 mm) spools.
When a slight force is needed to turn spool, tension is set.
Tools Needed:
15/16 in.
Ref. 805 023-A
3-13. Electrical Service Guide
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
60 Hz Single Phase
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In
Normal Operating Fuses
3
AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
200
230
460
575
200
230
460
575
69
61
30
24
34
30
15
12
80
70
35
25
40
35
15
10
100
90
40
35
50
45
20
15
Amperes1
Time-Delay Fuses 2
Min Input Conductor Size In
60 Hz Three Phase
6
8
10
12
10
10
14
14
101
(31)
86
(26)
229
(70)
217
(66)
86
(26)
114
(35)
178
(54)
227
(85)
8
8
10
12
10
10
14
14
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
NOTICE − This unit is either a 200/230/460 ac input voltage model or 460/575 ac input voltage model. See rating label on unit and check voltage
available at site to be sure it matches the voltage specified on the rating label.
OM-1327 Page 19
.
A complete Parts List is available at www.MillerWelds.com
3-14. Selecting Input Voltage (200/230/460 Volt Models Only)
!
. Be sure to reinstall all four screws
securing relinking board in place.
Turn Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
to Section 6-3 before
proceeding.
. Check input voltage available
1
at site.
. Incorrect linking can damage
unit and void the warranty.
1
Voltage Selection View
Window
Check voltage selected in unit.
Changing selection is only necessary if selected value does not
match available input voltage.
2
3
4
5
Relinking Board PC6
Mounting Screws
Receptacle RC23
(Connection For 230 VAC
Input Power)
Receptacle RC46
(Connection For 460 VAC
Input Power)
Move relinking board as needed
and connect plug PLG32 (in unit) to
RC23 or RC46 according to input
power voltage.
3
4
2
3
5
Tools Needed:
5/16 in.
803 539-C / 804 042-A
OM-1327 Page 20
.
A complete Parts List is available at www.MillerWelds.com
3-15. Serial Number And Rating Label Location
The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output.
For future reference, write serial number in space provided on back cover of this manual.
3-16. Selecting A Location And Connecting 3-Phase Input Power
!
3
Do not move or operate
unit where it could tip.
= GND/PE Earth Ground
5
8
3
18 in. (457 mm)
for airflow
L1
L2
L3
4
6
7
2
1
Rear Panel
Tools Needed:
Ref. 803 543-E / 803 766-A
!
Installation must meet all National and
Local Codes - have only qualified
persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input
conductors from unit.
!
Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
!
Warning: This unit is either a
200/230/460 ac input voltage model or
460/575 ac input voltage model. See
rating label on unit and check voltage
1
2
3
4
5
6
7
available at site to be sure it matches
the voltage specified on the rating
label.
conductor to disconnect device grounding
terminal first.
Input Power Cord Strain Relief
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 input conductors L1, L2, and L3 to
disconnect device line terminals.
Connect green or green/yellow grounding
8
Over-Current Protection
Select type and size of over-current
protection using Section 3-13 (fused
disconnect switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
OM-1327 Page 21
.
A complete Parts List is available at www.MillerWelds.com
3-17. Selection A Location And Connecting 1-Phase Input Power
!
1
Do not move or operate
unit where it could tip.
9
=GND/PE Earth Ground
11
8
10
L1
3
L2
18 in. (457 mm)
for airflow
5
3
4
5
2
1
6
7
Rear Panel
2
Tools Needed:
Ref. 803 543-E / 803 766-A
!
Installation must meet all National and
Local Codes - have only qualified
persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input
conductors form unit.
!
Always connect green or green/yellow
conductor to supply grounding terminal
first, and never to a line terminal.
!
Warning: This unit is either a
200/230/460 ac input voltage model or
460/575 ac input voltage model. See
rating label on unit and check voltage
available at site to be sure it matches
the voltage specified on the rating
label.
OM-1327 Page 22
Three Conductor Power Cord Preparation
9
1
2
3
10 Disconnect Device Line Terminals
4
5
6
7
Input Power Cord Strain Relief
Input Power Cord
Black And White Input Conductors (L1
And L2)
Red Input Conductor
Green Or Green/Yellow Grounding
Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor as shown.
Disconnect
Device
Connections
8
Input
Power
Disconnect Device (switch shown in
the OFF position)
Disconnect Device Grounding Terminal
Connect green or green/yellow grounding
conductor (see Item 5) to disconnect device
grounding terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protection using Section 3-13 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
.
A complete Parts List is available at www.MillerWelds.com
3-18. Threading Welding Wire For MIG Gun
1
2
3
4
5
6
7
8
7
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Intermediate Wire Guide
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
Lay gun cable out straight.
1
2 3
5
4
8
6
Tools Needed:
. Hold wire tightly to keep
it from unraveling.
6 in.
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
. Use pressure indicator scale to set
Tighten
a desired drive roll pressure.
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Pressure
Indicator
Scale
Remove gun nozzle and contact tip.
Turn On.
Tighten
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle
1
2
3
4
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
803 570-C / S-0627-A
OM-1327 Page 23
.
A complete Parts List is available at www.MillerWelds.com
3-19. Threading Welding Wire For XR Edge, XR-A Gun, XR-A Python, Or XR - Aluma-Pro
1
2
3
4
5
6
7
8
7
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Intermediate Wire Guide
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
Lay gun cable out straight.
8
1
2
3
4
5
Tools Needed:
6
. Hold wire tightly to keep
IMPORTANT!
For Aluminum Push-Pull welding.
Thread hub tension nut loosely
it from unraveling.
6 in.
(150 mm)
218243-A
Pull and hold wire; cut off end.
Open pressure assembly.
IMPORTANT!
For Aluminum
Push-Pull welding.
Tighten
1
2
3
4
Push wire thru guides into gun;
continue to hold wire.
Pressure
Indicator
Scale
21
43
218244-A
Close and tighten pressure
assembly, and let go of wire.
. Use pressure indicator scale to
set front drive roll pressure to 1
and rear drive roll pressure to
less than 1.
See Section 3-20 for threading
welding wire through XR guns.
Ref. 803 544-B / 218 243-A / 218 244-A / S-0627-A
OM-1327 Page 24
.
A complete Parts List is available at www.MillerWelds.com
3-20. Threading Welding Wire Through XR Guns
!
Welding wire is electrically live
when gun trigger is used to jog
wire.
. Refer to Section 3-19 for instructions
For XR-A Edge Gun:
on feeding wire through welding power source.
1
1
Pressure Roll Assembly
Lay gun cable out straight.
Open top cover, and open pressure roll assembly. If not already done, remove gun
barrel assembly.
Turn On
Welding Power
Source.
Remove barrel assembly before
threading wire through gun.
Press gun trigger until about 4 in. (102 mm)
of wire is sticking out front of gun. Insert
wire into barrel liner and tighten barrel assembly. Install correct size contact tube
and install collet nut.
Close top cover on gun. Press trigger
switch until about 6 in. (152 mm) of wire is
sticking out end of contact tip. Cut off wire.
Close and latch door.
. XR Edge gun drive roll pressure
should be set at minimum.
For XR-A Pistol Gun:
2
3
1
Pressure Roll Assembly
2
Drive Roll
3
Thumbscrew
Lay gun cable out straight. Open top
cover, and lift pressure arm and open
pressure roll assembly. If not already
done, remove gun barrel assembly.
Manually thread wire along drive roll
groove. Close pressure roll assembly.
Press gun trigger until about 4 in. (102 mm)
of wire is sticking out front of gun. Insert
wire into barrel liner and tighten barrel assembly. Install correct size contact tube
and install collet nut. Reinstall gun cover.
1
Turn On
Welding Power
Source.
4
Pressure Adjustment Knob
See final pressure adjustment at bottom of
page.
Remove barrel assembly
before threading wire
through gun.
For XR-A Pistol Gun:
Nonconductive
Surface
Tools Needed:
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
. Do not exceed midrange setting.
Cut off wire. Close and latch door.
!
Turn welding power source Off.
Ref. 802 193-A / 801 556 / Ref. 151 666-C
OM-1327 Page 25
.
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − OPERATION
4-1. Controls
11
10
1
2
12
3
4
7
5
6
8
1
Pulse Indicator Light
. Pulse only lights if unit has the pulse
MIG module and is programmed for
pulse MIG.
2
MIG Indicator Lights
Pulse (1) and MIG (2) illuminate to Indicate
weld mode of unit.
3
Process Light
PROCESS illuminates when unit is in
Process select menu.
4
Wire Light
WIRE illuminates when unit is in Pulse MIG
program select menu.
5
Timers Light
TIMERS illuminates when unit is in Timers
menu.
6
Setup Button
9
Use button to access Timers, Process and
Wire menus.
7
Arc Control Button
Use button to select either inductance
control in MIG welding mode or Sharp Arc
in Pulse MIG welding mode.
8
Left Knob
Use knob to adjust volts in MIG welding
mode or change parameter values in
Setup.
9
Right Knob
Use knob to adjust wire speed in MIG
welding mode or change parameter values
in Setup.
10 Left Display
11 Right Display
Ref. 213 935-A
12 Weld Functions/Setup Indicator
Lights
VOLTS illuminates in MIG welding mode
indicating volts in left display can be
adjusted. Also, VOLTS lights to indicate left
display is showing actual voltage during
welding and for 5 seconds after the arc is
extinguished.
ARC LENGTH illuminates in Pulse MIG
welding mode indicating Arc Length can be
adjusted.
SETUP illuminates when a parameter on
the corresponding display above the light
can be adjusted.
WIRE SPEED illuminates in either Pulse
MIG or MIG welding mode indicating wire
speed can be adjusted.
AMPS illuminates indicating welding amps
appears in the display, instead of wire
speed, during welding and for 5 seconds
after the arc is extinguished.
. The first time the welding power source is energized it starts in MIG welding mode. Each time after the initial startup, when the unit is turned off,
whatever mode and parameter settings were last set will remain as the current settings the next time the unit is energized.
4-2. MIG Mode
In MIG mode, VOLTS is lit under left display and WIRE SPEED is lit under right display. Left knob is used to adjust
welding voltage within a range of 10-32 volts, and right knob is used to adjust wire feed speed within a range of 25-700
IPM. Refer to weld chart in front compartment for proper parameter settings according to wire type, shielding gas, and
material type and thickness.
4-3. Jog Mode
If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld
power. For MIG guns, shielding gas will shut off after 1 minute, and for spool guns, shielding gas will continue to flow
OM-1327 Page 26
.
A complete Parts List is available at www.MillerWelds.com
because gas valve is located inside spool gun. For MIG guns, wire will feed for up to 2 minutes while trigger is pressed,
then wire drive system in unit will automatically shut off. For spool guns, wire will feed for up to 30 seconds before
shutting off. If gun trigger is pressed for 3 seconds without striking an arc the displays will show JOG MODE.
4-4. Weld Status
When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage will be
shown on the displays for 5 seconds. The VOLTS and AMPS indicator lights will illuminate under the displays and each
value will appear in the corresponding display.
If a programmed value requires adjustment after the arc is extinguished and during the 5 seconds display of actual
values, turning either knob will cause actual values in the displays to be replaced by programmed values for
adjustment purposes.
. The 5 second delay after the arc is extinguished for displaying actual weld values can be turned on or off in the Timer menu DISP selection (see
Section 5-3).
4-5. MIG Gun-On-Demand
The guns that can be used with this unit are MIG guns, spool guns, and push-pull guns. To switch from one gun to
another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is
pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun.
If the unit is powered down and back on again, the gun last used will become the current active gun.
4-6. Pulse MIG Mode Voltage Adjustment
In Pulse MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire
feed speed. Arc Length adjustment is used to adjust actual arc length which automatically adjusts the voltage. See
weld chart in front compartment for proper wire feed speed adjustment according to wire size and type.
4-7. Pulse MIG Gun-On-Demand
The spool gun functions slightly different in Pulse MIG mode. To switch from one gun to another, momentarily press the
trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data
and both displays will show the last programmed values for that particular gun. For a spool gun, the wire speed is taken
from the position of the gun potentiometer. This wire speed value is automatically adjusted if the potentiometer is
moved since the last time the gun was active. If the unit is powered down and back on again, the gun last used will
become the current active gun.
4-8. Tip Saver
If gun contact tip is directly shorted to the workpiece while gun trigger is pressed, the welding arc automatically shuts
off after 1 second to prevent wire burnback in the contact tip.
OM-1327 Page 27
OM-1327 Page 28
23.0 /220
28.5 /485
29.3/530
USE
.035
.045
Steel
Inductance = 30
3/64 5356
.035 5356
24.0/535
24.0/475
−
3/64 4043
23.5/500
23.5/800
23.5/435
23.5/700
−
.035 4043
100% Argon
Aluminum
27.0/425
29.0/475
.045
90% Argon
10% Co 2
−
Metal Core
Inductance = 30
25.0 /450
−
−
.035
.045
Inductance = 60−80
Stainless Steel
90% Helium
7.5% Argon
2.5% Co 2
Inductance = 20−40
75% Argon
25% Co 2
SPRAY
23.0 /325
−
.045
.035
2
100% Co
Steel
3/8”
(9.5mm)
Inductance = 20−40
Wire
Gas
Material
1/2”
(12.7mm)
−
22.5 /465
23.0/660
23.0/375
21.0 /375
21.0/520
21.5/305
21.5/450
24.5/350
26.0/400
23.0/530
23.0/300
21.5 /375
18.0 /200
18.5 /275
20.5 /175
20.5 /240
3/16”
(4.8mm)
24.0/400
22.5/440
19.0/220
19.5 /330
21.5 /200
21.5 /280
1/4”
(6.4mm)
19.0 /340
19.0/450
19.5/250
19.2/380
23.5/300
20.5/250
21.0/325
17.5 /170
18.0 /260
20.0 /150
20.0/210
1/8”
(3.2mm)
to be modified for other types of welding joints or welding positions.
Note: All chart parameters reference settings for Horizontal T fillet welds. Settings may need
MIG CHART
−
−
18.2/300
19.5/175
18.0/235
16.0/130
16.0/155
18.5/105
18.5/160
16ga
(1.6mm)
20.0/235
20.0/275
16.2 /150
16.5 /200
19.0 /110
19.0 /175
14ga
(2.0mm)
−
−
17.5/150
−
15.0/100
−
17.0/90
20ga
(0.9mm)
23.5 /220
Reference
Volts/Wirefeed
−
19.0/160
18.5/200
15.5/100
15.5/135
−
18.0/115
18ga
(1.2mm)
MIG CHART
−
−
−
−
14.5/95
−
16.5/80
22ga
(0.8mm)
.
A complete Parts List is available at www.MillerWelds.com
4-9. Weld Parameters For MIG Mode
Gas
90%Argon
10%Co 2
Ar/He/CO2
Tri-Mix
90%Argon
10%Co 2
100%Argon
Material
Steel
StainlessSteel
MetalCore
Aluminum
350
550
—
3/645356
PULSECHART
HAR
.0355356
390
—
450
—
3/644043
650
750
.0354043
150
300
405
720
325
550
350
640
260
450
325 250
200
400
300
450
500
300
400
550
200
3/16”
(4.8mm)
1/4”
(6.4mm)
3/8”
(9.5mm)
475 400
450
.045
600
.045
500
.035
650
.045
1/2”
(12.7mm)
.035
Wire
All chart parameters are based
on the following defaults:
arc length − 50, Sharparc[ − 25.
290
450
200
310
200
125
200
150
250
1/8”
(3.2mm)
165
245
110
185
125
75
150
100
150
16ga
(1.6mm)
—
—
—
—
19ga
(1.0mm)
115
200
90
150
—
150
75
130
—
—
—
—
—
—
—
—
22ga
(0.8mm)
115——
50
100
75
85
18ga
(1.2mm)
PULSECHART
190
310
140
210
150
100
175
125
200
14ga
(2.0mm)
WELDCHARTS
.
A complete Parts List is available at www.MillerWelds.com
4-10. Weld Parameters For Pulse Mode
OM-1327 Page 29
.
A complete Parts List is available at www.MillerWelds.com
SECTION 5 − PROGRAMMING
5-1. MIG Welding Mode
1
2
3
4
7
5
6
8
9
Ref. 213 935-A
When the MIG light (2) is illuminated, the
unit is in MIG Welding mode.
SETUP
To enter MIG welding mode, depress the
SETUP (6) button once to go to GUN
selection. Rotate the right knob (9) to select
the gun being used. Select MIG for standard
MIG gun, or select XR‐A, EDGE, PYTH alpr
for push pull guns, or SPL for spoolgun.
Depress SETUP (6) a second time to
illuminate the PROCESS (3) light. Rotate
right knob (9) until MIG is displayed (for MIG
only units NOT USED will be displayed).
OM-1327 Page 30
Depress SETUP (6) button again to
illuminate the WIRE (4) light. This menu is
not used in MIG Welding mode.
Depress SETUP (6) button again to
illuminate TIMERS (5) light. For description
of the TIMERS, refer to TIMERS menu
(see Section 5-3)
If crater fill function menus are enabled,
TIMERS light will stay on to allow for adjustment of crater parameters and timers (see
Section 5-6).
Depress SETUP (6) button again to exit
menus and enter MIG welding mode.
OPERATION
Adjust welding Voltage with left knob (8)
and Wire Feed Speed with right knob (9).
Refer to MIG welding chart for proper
Voltage and Wire Feed Speed setting in
reference to material type, material
thickness, wire, and gas (see Section 4-9).
ARC CONTROL
MIG welding mode: Depress ARC
CONTROL (7) button to enter Arc control
menu and INDU will appear on the left
display and the corresponding setting will
appear on the right display. Adjust right
knob (9) to adjust inductance setting. In
MIG welding mode the Arc control is an
inductance control from 0-99. Refer to MIG
welding chart for suggested Inductance
setting for the wire and gas types being
used (see Section 4-9). Changing the
inductance will change the fluidity of the
puddle.
Low Inductance
Weld Bead
(0 setting)
High Inductance
Weld Bead
99 setting
.
A complete Parts List is available at www.MillerWelds.com
5-2. Pulse MIG Welding Mode
1
2
3
4
7
5
6
8
9
Ref. 213 935-A
When the PULSE MIG (1, 2) is illuminated,
the unit is in Pulse MIG Welding mode.
SETUP
To enter Pulse MIG welding mode, depress
the SETUP (6) button once to go to GUN
selection. Rotate the right knob (9) to select
the gun being used. Select MIG for standard
MIG gun, or select XR‐A, EDGE, PYTH alpr
for push pull guns, or SPL for spoolgun.
Depress SETUP (6) a second time to
illuminate the PROCESS (3) light. Rotate
right knob (9) until PULS is displayed.
Depress SETUP (6) button again to
illuminate the WIRE (4) light. Adjust left
knob (8) to select wire type, adjust right
knob (9) to select wire size.
Depress SETUP (6) button again to exit
WIRE menu and enter TIMERS (5) menu.
The TIMERS (5) light will illuminate. For
description of the TIMERS, refer to
TIMERS menu (see Section 5-3)
If crater fill function menus are enabled,
TIMERS light will stay on to allow for adjustment of crater parameters and timers (see
Section 5-6).
Depress SETUP (6) button again to exit
menus and enter PULSE welding mode.
OPERATION
ARC CONTROL
Adjust right knob (9) for proper Wire Feed
speed and adjust left knob (8) to change
Arc Length if required. Arc length will default to 50 if never adjusted previously. Refer to Pulse MIG welding chart for proper
Wire Speed setting for metal and metal
thickness being welded (see Section 4-9).
All Pulse MIG programs are setup with the
gases listed in the Pulse MIG welding
chart. If alternate gases are used, adjust
Arc Length and/or Sharp Arc (Arc Control) (7) to adjust arc characteristics.
Pulse MIG (1, 2) welding mode: Depress
ARC CONTROL (7) button to enter Arc
Control menu for sharp arc. SHRP will appear on the left display and the corresponding setting will appear on the right display.
The setting can be adjusted from 0-50 and
all Pulse MIG welding programs are designed with a setting of 25. Adjusting the
Sharp Arc setting will vary the width of the
welding arc cone.
ARC LENGTH
(0 Setting)
Arc length can be adjusted from 0-99. All
Pulse MIG programs are set with a value of
50. Adjusting the Arc Length will vary the
length of the welding arc cone.
(0 Setting)
(99 Setting)
Low Setting
(50 Setting)
High Setting
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
Sharp Arc can be adjusted to help customize your arc to the gas being used.
Low Setting
High Setting
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
Arc Length can be adjusted to help customize your arc to the gas being used.
OM-1327 Page 31
.
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5-3. Timers
1
2
3
4
7
5
6
8
9
Ref. 213 935-A
To enter the TIMERS (5) menu depress the
SETUP (6) button 4 times or until the
TIMERS light (5) is illuminated.
depressed and before the welding arc will
be allowed to be active. Range of setting is
from 0-5 seconds.
Items that can be adjusted in this menu are:
Postflow (POST) − The amount of time that
the shielding gas will flow after the arc has
been shut off. Range of setting is 0-10
seconds.
Run-in speed (R‐IN) − The speed of the
wire prior to the welding arc being struck.
This setting is a percentage of the Wire
Feed Speed the unit is set to for welding.
Programming value ranges from 25-150.
Preflow (PRE) − The amount of time that the
shielding gas will flow after the trigger is
OM-1327 Page 32
Spot Timer (SPOT) − The amount of time
that the arc will be active before it shuts off
automatically. Range of setting is from
0-120 seconds. Spot timer is reset upon release of welding gun trigger.
Display (DISP) − Allows the Wire Speed
display to show actual welding amperage
while arc is active and for 5 seconds after
arc is shut off. Setting is either AMPS or
WFS for standard Wire Feed Speed.
Once in the TIMERS (5) menu, rotate the
left knob (8) to find a particular item, and rotate the right knob (9) to change setting or
status.
Depress SETUP (6) button to get out of
TIMERS (5) menu and to enter welding
mode.
.
A complete Parts List is available at www.MillerWelds.com
5-4. Arc Times, Arc Starts, Hot Start (Aluminum Pulse Only), And Crater Fill
. Accessing the Arc Times, Arc Starts, Hot Start (aluminum pulse only), and
Crater Fill data will also allow access to Software Version data and Motor
Calibration function. The software version data and motor calibration function are for use by factory authorized service personnel only.
Do not use the motor calibration function if it appears on the displays.
2
1
3
Arc times and number of arc starts are
saved in unit memory. To view this
information, press both SETUP (1) and
ARC CONTROL (2) buttons at the same
time.
Left display will initially show arc hours.
Rotate left knob (3) and display will change
to show number of arc starts.
4
To turn on the Crater Fill display, rotate left
knob (3) until CRTR appears in the left
display. The factory default for Crater Fill
display is OFF which appears in the right
display. Rotate the right knob (4) until ON
appears in the display.
Ref. 213 935-A
. The Crater Fill display can be turned
off after parameters are set in programs, but remember that once crater
fill is turned on in any program, it will
remain on even though it does not appear in the displays because Crater
Fill display is turned off.
To exit this menu, press either the SETUP
(1) or ARC CONTROL (2) button, or press
a gun trigger on any welding gun
connected to the unit.
OM-1327 Page 33
.
A complete Parts List is available at www.MillerWelds.com
5-5. Setting Hot Start (Aluminum Pulse Only) Parameters
. The factory default setting for Hot Start is “Auto” on 350P models. The Auto setting has
preset parameters. Hot Start can also be set to “On” (manual) for customized settings
or made inactive when set to Off.
2
1
3
4
Ref. 213 935-A
To access the Setup Feature Menu, press
both SETUP (1) and ARC CONTROL (2)
buttons at the same time.
Left display will initially show arc hours.
Rotate left knob (3) until
the left display.
ALST appears in
Rotate right knob (4) to select hot start
mode as follows:
Auto − default setting for preset hot start
parameters
Off − hot start is inactive
On − allows customized setting of hot start
parameters
OM-1327 Page 34
Manual Hot Start Mode
When ALST appears in the left display and
On appears in the right display, the welding
power source is set for manual hot start
mode.
To access hot start parameters, press the
SETUP (1) button until SPWR appears in
the left display.
SPWR − Start Power
Range for start power is 100-250 as a percent of wire feed speed.
. SPWR maximum setting will depend
on set wire feed speed and may not
allow a setting of 250 under certain
conditions.
STMR − Start Time
Time range is 0.0-0.5 seconds for hot start
to be on.
STRL − Start Arc Length
Range for start arc length is 0-99 that
changes arc length from shorter to longer.
RMPT − Ramp Time
Time range is 0.1-5.0 for the time it takes to
go from hot start to set wire feed speed.
. The two parameters that will have the
largest influence on hot start are Start
Power and Start Time. These two parameters will determine how much
heat is provided and for how long at
the beginning of the weld.
To exit this menu, press the SETUP (1)
button.
.
A complete Parts List is available at www.MillerWelds.com
5-6. Setting Crater Fill
. Crater parameters are welding gun independent (i.e. crater fill can be on for a spool
gun and off for a MIG gun). When using the same welding gun, MIG and pulse programs are independent of each other; however, crater parameters will be the same
for all pulse programs. For example, if a MIG gun is using the .035 steel pulse program, and crater fill is on and parameters are set, crater will also be on and the
same parameters will be set for a stainless pulse program.
1
2
3
To set Crater Fill, select a program and
press SETUP (1) until the TIMERS LED
turns on. Press SETUP again and the left
display will show CRTR and the right display
will show OFF.
Rotate left knob (2) to change display to
TIME, and rotate right knob (3) to set crater
time. Time range is 0.1-5.0 seconds (see
Section 5-7).
Rotate right knob (3) to turn crater ON.
Rotate left knob (2) to change display to
WFS, and rotate right knob (3) to set crater
wire feed speed. Wire feed speed range is
50-700 IPM (see Section 5-7).
Rotate left knob (2) to change display to
VOLT (MIG program) or ARCL (pulse
program), and rotate right knob (3) to set
either volts (range is 10.0-32.0 volts) or arc
length [range is 0-99 (see Section 5-7)].
Ref. 213 935-A
Rotate left knob (2) to change display to
TDLY for time delay. This setting is for spot
or skip welding without crater fill if the arc
time is less than the set time. Time range is
0.0-5.0 seconds (i.e. if TDLY is set for 2.0
seconds, weld operation will not go into
crater if gun trigger is released before 2.0
seconds).
To exit this menu, press the SETUP (1)
button.
OM-1327 Page 35
.
A complete Parts List is available at www.MillerWelds.com
5-7. Recommended Crater Fill Parameters
Recommended Crater Parameters
What Process
are You Using?
What Material
are You Welding?
Suggested Suggested
Wire Types Shielding Gases
Wire Sizes
(Diameter)
1/2”
(12.7mm)
M
I
G
P
U
L
S
E
OM-1327 Page 36
.
3/8”
1/4”
A complete Parts List is available at www.MillerWelds.com
3/16”
1/8”
19ga.
20ga.
(1.05mm)(0.9mm)
SC-187 212-A
OM-1327 Page 37
.
A complete Parts List is available at www.MillerWelds.com
5-8. System Reset
. Accessing the System Reset function will also allow access to Timer Reset (RTMR)
and Option Reset (ORST) functions. The timer reset and option reset functions are
for use by factory authorized service personnel only.
Do not use the timer reset or option reset functions if they appear on the displays.
1
Ref. 213 935-A
A system reset function is available that
completely resets unit back to all the
original factory settings.
To access this menu, turn on welding power
source, then press the SETUP (1) button
when the SETUP light illuminates under the
Left display.
OM-1327 Page 38
SRST will appear on the left display and OFF
will appear on the right display.
To prepare the unit for system reset, rotate
right knob until ON appears on the right
display.
To apply the system reset function, press
SETUP (1) button, and wait until unit
completely reboots before performing any
other operations.
.
A complete Parts List is available at www.MillerWelds.com
5-9. Motor Calibration Function
5
3
6
1
2
Perform this function after replacing wire
drive motor and/or control circuit board.
The
motor
calibration
function
automatically calibrates the wire drive
motor to enhance arc starting performance
and consistency.
. To
obtain the most accurate
calibration, set up welding power
source in MIG welding mode.
Turn on unit input power.
1 Setup Button
2 Left Knob
4
3
Left Display
4
Right Knob
5
Right Display
6
Arc Control Button
Open drive rolls in welding power source
and in push/pull gun if one is attached to
unit.
Simultaneously press Setup and Arc
Control buttons.
Rotate left knob until MCAL is displayed.
Rotate right knob until YES is displayed.
Ref. 213 935-A
Press and hold gun trigger. Wire drive
speed will be overridden to 50 IPM for 12
seconds and then to 800 IPM for 12
seconds.
When CAL DONE appears on the display,
release gun trigger.
Data save will appear on the display while
the calibration data is being stored in the
Control board memory.
Close drive rolls in welding power source and
push/pull gun.
This completes the motor calibration function,
and normal operation can resume.
OM-1327 Page 39
.
A complete Parts List is available at www.MillerWelds.com
. Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.
5-10. Set Up Push Motor Torque (SUP)
5
3
6
1
2
1
Setup Button
2
Left Knob
3
Left Display
4
Right Knob
5
Right Display
6
Arc Control Button
Simultaneously press Setup and Arc Control
buttons.
OM-1327 Page 40
4
Rotate the left knob counterclockwise
(CCW) to find the particular item, and rotate
the right knob to change the setting.
The following items can be adjusted by
rotating the left knob counterclockwise
(CCW):
Set up Push Motor Torque (SUP) − This
feature is only active when a push/pull gun
is connected to the welding power source.
The (SUP) setting will adjust the
Ref. 213 935-A
over-torque limit of the push motor inside
the welding power source. The range is
0-250 and the default value is 130.
Increasing this setting will increase the
over-torque limit and speed up the remote
wire feed speed motor.
. If Aluma-Pro push/pull gun has a
listed SUP value, set the power
source to match the SUP value.
.
A complete Parts List is available at www.MillerWelds.com
SECTION 6 − MAINTENANCE &TROUBLESHOOTING
6-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Disconnect power
before maintaining.
. Maintain more often
l = Replace
during severe
conditions.
Reference
Every
3
Months
l Damaged Or Unreadable
Labels
Every
6
Months
l Repair Or Replace
Cracked Weld Cable
~ Clean And Tighten Weld
Terminals
n Check Gun Cable
OR
~ Inside Unit
~ Clean Drive Rolls
6-2. Overheating
Thermistors RT1 and RT2 protect the unit from damage due to overheating. If output diode heatsink or IGBT heatsink
gets too hot, RT1 and/or RT2 opens and output stops. The fan keeps running to cool the unit. Wait several minutes
before trying to weld.
OM-1327 Page 41
.
A complete Parts List is available at www.MillerWelds.com
6-3. Measuring Input Capacitor Voltage
!
3
Significant DC voltage can
remain on capacitors after
unit is Off. Always check capacitors as shown to be sure
they have discharged before
working on unit.
Turn Off welding power source and
disconnect input power.
3
Remove case.
1
2
1
Input Capacitor C3 Terminals
2
Input Capacitor C4 Terminals
3
Voltmeter
Check input capacitors as shown.
Measure the dc voltage across the
positive (+) and negative (−)
terminals until voltage drops to near
0 (zero) volts.
Proceed with job inside unit.
Reinstall case when finished.
Tools Needed:
5/16 in.
221 044-A / Ref. 803 550-B
OM-1327 Page 42
.
A complete Parts List is available at www.MillerWelds.com
6-4. Changing Drive Roll and Wire Inlet Guide
1
2
.045 Groove
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
.035 Groove
5
Stamped
.035
Securing Screw
Inlet Wire Guide
Stamped
.045
3
Intermediate Guide
4
Drive Roll
. The drive assembly comes
equipped
with
factory
installed .035/.045 combination drive rolls. Be sure that all
4 drive rolls are installed correctly.
2
Combination drive rolls consist of
two different sized grooves. The
stamped markings on the end surface of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to the
carrier gear is the groove for the
wire size viewed on the end surface
of the drive roll.
1
Install correct drive roll for wire size
and type.
. U-Grooved drive rolls are reTools Needed:
5/64 in.
7/16 in.
quired for feeding aluminum
wire.
4
1
5
3
Drive Roll Securing Nut
Turn nut one click to secure drive
roll.
802 520-B
OM-1327 Page 43
.
A complete Parts List is available at www.MillerWelds.com
6-5. Help Displays
V
A
HELP
V
0
A
HELP
V
A
HELP
V
3
A
HELP
V
HELP
V
5
V
HELP
MM
V
A
HELP
TIP
V
A
6
MM
V
A
7
9
A
10
A
HELP
V
4
A
HELP
V
A
8
HELP
V
2
A
HELP
V
1
HELP
V
V
JOG
11
A
SAVE
A
350P
A
350
A
XXX
Displays a jog wire feed speed.
OM-1327 Page 44
.
A complete Parts List is available at www.MillerWelds.com
. All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
S
Help 0
Indicates overheating on left side of unit
(displays flash between OVER TEMP and
HELP 0). Unit will shutdown until internal
temperature drops within operational range.
S
Help 1
Turn off primary input power and check input
voltage per primary voltage rating of welder,
and correct if necessary. If HELP 1 persists,
this Indicates a communication error
between control board PC1 and user
interface board. Contact nearest Factory
Authorized Service Agent.
S
Help 2
Indicates overheating on right side of unit
(displays flash between OVER TEMP and
HELP 2). Unit will shutdown until internal
temperature drops within operational range.
S
Help 3
Indicates gun trigger was pulled and held
during power up. Release gun trigger and
clear fault condition. Also, this display can
Indicate no open circuit voltage detected
when gun trigger is pulled and no arc
detected within 3 seconds. Turn off primary
input power and contact a Factory
Authorized Service Agent.
S
Help 4
Indicates gun trigger was pulled and held for
2 minutes without a welding arc established
or there is a direct short between contact tip
or wire and the workpiece. Release gun
trigger and clear fault condition.
S
Help 5
Indicates a malfunction in wire feed system
and/or drive motor overcurrent condition.
Check for proper spool brake adjustment or
obstructions in wire feed system. Clean or
replace liner, wire guides, or contact tip.
S
Help 6
Indicates a malfunction in wire feed system
and/or external drive motor overcurrent condition (spool gun or push-pull gun). Check for
proper spool brake adjustment or
obstructions in wire feed system. Clean or
replace liner, wire guides, or contact tip.
S
Help 7
Indicates input voltage malfunction (voltage
too high or too low) causing unit to
automatically shut down. Turn off input
primary power and check input voltage per
primary voltage rating of welder. Unit will
operate once input voltage is within
specification and power to unit is turned off
and back on.
S
Help 8
Indicates a malfunction in the secondary
power circuit of the unit. Check control board
PC1, and primary and secondary
connections.
S
Help 9
Indicates a malfunction in Pulse MIG
function. Check connection between pulse
board and user interface board. Replace
pulse board, if necessary.
S
Help 10
Indicates a trigger error when two gun
triggers are activated at the same time.
Release gun triggers to clear error.
S
Help 11
Indicates a tach error when tach feedback
signal is not present. Release and press gun
trigger to reset tach signal. If error continues,
contact a Factory Authorized Service Agent.
S
Tip Save
Indicates contact tip is directly shorted to
workpiece. Arc shuts off in this condition,
and message resets when tip is not touching
workpiece and gun trigger is released.
S
MM 350P
When unit is turned on, this display indicates
that pulse option is installed and operational.
S
MM 350
When unit is turned on, this display indicates
that unit is either a MIG only machine or
pulse option is installed but not operational.
S
Jog XXX (Wire Feed Speed)
Indicates trigger is pressed, but no arc is
detected. Wire feed speed goes to Jog wire
feed speed after 3 seconds.
SC-187 212-A
OM-1327 Page 45
.
A complete Parts List is available at www.MillerWelds.com
6-6. Troubleshooting
Trouble
Remedy
No weld output; wire does not feed.
Be sure line disconnect switch is On (see Section 3-16 or 3-17).
Replace building line fuse or reset circuit breaker if open (see Section 3-16 or 3-17).
Secure gun trigger connections (see Section 3-7).
Have Factory Authorized Service Agent check Power switch.
Have Factory Authorized Service Agent check all board connections and main control board.
No weld output; wire feeds.
Thermistor RT1 or RT2 open (overheating). Allow fan to run; the unit will be enabled when it has cooled
and temperatures are within acceptable limits (see Section 3-2 and 6-2).
Connect work clamp to get good metal to metal contact.
Replace contact tip (see gun Owner’s Manual).
Have Factory Authorized Service Agent check main control board and main rectifier.
Low weld output.
Connect unit to proper input voltage or check for low line voltage (see Section 3-16 or 3-17).
Have Factory Authorized Service Agent check main control board and user interface board.
Low, high, or erratic wire speed.
Readjust front panel settings (see Section 4-1).
Change to correct size drive rolls (see Section 6-4).
Readjust drive roll pressure (see Section 3-18).
Replace inlet guide, contact tip, and/or liner if necessary (see gun Owner’s Manual).
Have Factory Authorized Service Agent check input voltage.
Have Factory Authorized Service Agent check main control board.
No wire feed.
Turn Wire Speed control to higher setting (see Section 4-1).
Clear obstruction in gun contact tip or liner (see gun Owner’s Manual).
Readjust drive roll pressure (see Section 3-18).
Change to correct size drive rolls (see Section 6-4).
Rethread welding wire (see Section 3-18).
Check gun trigger and leads. Repair or replace gun if necessary.
Have Factory Authorized Service Agent check main control board and user interface board.
H − − message appears on voltmeter and ammeter displays to indicate thermistor RT1 or RT2 is open
and unit is in an overheated condition (see Section 6-5).
OM-1327 Page 46
Notes
OM-1327 Page 47
SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram For Welding Power Source
OM-1327 Page 48
246 030-A
OM-1327 Page 49
SECTION 8 − PARTS LIST
8-1. Drive Roll And Wire Guide Kits
. Base selection of drive rolls upon the following recommended usages:
1 V-Grooved rolls for hard wire.
2 U-Grooved rolls for soft and soft shelled cored wires.
3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4 V-Knurled rolls for hard shelled cored wires.
5 Drive roll types may be mixed to suit particular requirements (e.g. V-Knurled
roll in combination with U-Grooved).
Wire Diameter
Kit No.
Fraction
Decimal
Metric
.023/.025 in
.023/.025 in
0.6 mm
087 132
.030 in
.030 in
0.8 mm
.035 in
.035 in
.045 in
Drive Roll
Part No.
Wire Guide
Type
Inlet
Intermediate
087 130
V-Grooved
056 192
056 206
046 780
053 695
V-Grooved
056 192
056 206
0.9 mm
046 781
053 700
V-Grooved
056 192
056 206
.045 in
1.2 mm
046 782
053 697
V-Grooved
056 193
056 207
.052 in
.052 in
1.3 mm
046 783
053 698
V-Grooved
056 193
056 207
1/16 in
.062 in
1.6 mm
046 784
053 699
V-Grooved
056 195
056 209
.035 in
.035 in
0.9 mm
044 750
072 000
U-Grooved
056 192
056 206
.045 in
.045 in
1.2 mm
046 785
053 701
U-Grooved
056 193
056 207
.052 in
.052 in
1.3 mm
046 786
053 702
U-Grooved
056 193
056 207
1/16 in
.062 in
1.6 mm
046 787
053 706
U-Grooved
056 195
056 209
.035 in
.035 in
0.9 mm
046 792
132 958
V-Knurled
056 192
056 206
.045 in
.045 in
1.2 mm
046 793
132 957
V-Knurled
056 193
056 207
.052 in
.052 in
1.3 mm
046 794
132 956
V-Knurled
056 193
056 207
1/16 in
.062 in
1.6 mm
046 795
132 955
V-Knurled
056 195
056 209
Ref. S-0025-D
. A complete Parts List is available at www.MillerWelds.com
OM-1327 Page 50
Effective January 1, 2009
(Equipment with a serial number preface of LK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
* Accessory (Kits)
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Fume Extractors
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* ICE Plasma Cutting Torches (No Labor)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
* Work Stations/Weld Tables (No Labor)
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays, work station table tops and welding
curtains, or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend
models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
3.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2009−10
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2009 Miller Electric Mfg. Co.
2009−01
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